Graco 332637C Reactor 2 Elite Integrated Proportioning System Users Manual System, Repair Parts, English

2015-04-02

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Repair-Parts

Reactor® 2 Elite Integrated
Proportioning System

332637C
EN

Electric, Heated, Integrated Plural Component Proportioning System With Integrated Generator. For
spraying polyurethane foam and polyurea coatings. For professional use only. Not approved for use in
explosive atmospheres or hazardous locations.
Important Safety Instructions. Read all warnings and instructions in
this manual. Save these instructions.

PROVEN QUALITY. LEADING TECHNOLOGY.

Contents
Warnings .............................................................3
Important Isocyanate Information...........................9
Models............................................................... 11
Approvals........................................................... 13
Accessories........................................................ 13
Supplied Manuals............................................... 14
Related Manuals ................................................ 14
Troubleshooting.................................................. 15
Troubleshoot Errors ..................................... 15
Load Center Diagnostics .............................. 50
Pressure Relief Procedure .................................. 60
Shutdown........................................................... 61
Flushing............................................................. 64
Repair................................................................ 65
Before Beginning Repair............................... 65
Flush Inlet Strainer Screen ........................... 65
Drain Coolant .............................................. 66
Reﬁll Proportioner Coolant Loop ................... 68
Reﬁll Engine Coolant Loop ........................... 69
Coolant Speciﬁcations.................................. 70
Change Pump Lubricant............................... 70
Remove Pump............................................. 71
Install Pump ................................................ 72
Repair Drive Housing ................................... 73
Repair Electric Motor.................................... 76
Repair Circuit Breaker Module ...................... 77
Replace Load Center Relays and
Fuses ............................................ 79
Replace Load Center ................................... 80
Replace Engine Solenoid Relays .................. 80
Replace Fluid Inlet Sensor............................ 81
Replace Pressure Transducers..................... 81
Replace Fans .............................................. 82

Repair Booster Heater.................................. 84
Repair Heated Hose..................................... 87
Repair Fluid Temperature Sensor
(FTS)............................................. 88
Replace Heat Exchangers ............................ 91
Replace Power Supply ................................. 94
Replace Circulation Pump ............................ 95
Repair Filter Housing Filter ........................... 96
Remove Fuel Tank....................................... 96
Replace Battery ........................................... 97
Repair Fusible Link Harness......................... 98
Remove Radiator....................................... 100
Replace Advanced Display Module
(ADM).......................................... 100
Replace Engine Control Module.................. 101
Replace Motor Control Module
(MCM) ......................................... 101
Replace Temperature Control Module
(TCM).......................................... 101
Remove Proportioner ................................. 102
Repair Engine............................................ 105
12V Charge Alternator................................ 105
Notes ............................................................. 106
Parts................................................................ 107
Electrical Schematics........................................ 154
Repair and Spare Parts Reference .................... 170
Recommended Rebuild Spare Parts .................. 171
Dimensions...................................................... 172
Technical Speciﬁcations.................................... 175
Notes ............................................................. 178
Graco Extended Warranty for Integrated
Reactor® 2 Components ..................... 179

332637C

Warnings

Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-speciﬁc
risks. When these symbols appear in the body of this manual or on warning labels, refer back to these
Warnings. Product-speciﬁc hazard symbols and warnings not covered in this section may appear throughout
the body of this manual where applicable.

WARNING
ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can
cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before
servicing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualiﬁed electrician and comply with all local codes
and regulations.
Toxic ﬂuids or fumes can cause serious injury or death if splashed in the eyes or on skin,
inhaled, or swallowed.
• Read MSDSs to know the speciﬁc hazards of the ﬂuids you are using.
• Store hazardous ﬂuid in approved containers, and dispose of it according to applicable
guidelines.
• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning
equipment.
TOXIC FLUID OR FUMES

Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing
carbon monoxide can cause death.
• Do not operate in an enclosed area.
CARBON MONOXIDE HAZARD

Wear appropriate protective equipment when in the work area to help prevent serious injury,
including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective
equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the ﬂuid and solvent
manufacturer.
PERSONAL PROTECTIVE EQUIPMENT

332637C

Warnings

WARNING
SKIN INJECTION HAZARD

High-pressure ﬂuid from gun, hose leaks, or ruptured components will pierce skin. This may
look like just a cut, but it is a serious injury that can result in amputation.
.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deﬂect leaks with your hand, body, glove, or rag.
• Follow the
when you stop spraying and before cleaning, checking,
or servicing equipment.
• Tighten all ﬂuid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
Get immediate surgical

treatment

Pressure Relief Procedure

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in
can ignite or explode. To help
prevent ﬁre and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and
plastic drop cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when ﬂammable
fumes are present.
• Ground all equipment in the work area. See
instructions.
• Use only grounded hoses.
• Hold gun ﬁrmly to side of grounded pail when triggering into pail. Do not use pail liners unless
they are antistatic or conductive.
•
if static sparking occurs or you feel a shock Do not use
equipment until you identify and correct the problem.
• Keep a working ﬁre extinguisher in the work area.
work area

Grounding

Stop operation immediately

332637C

Warnings

WARNING
THERMAL EXPANSION HAZARD

Fluids subjected to heat in conﬁned spaces, including hoses, can create a rapid rise in pressure
due to the thermal expansion. Over-pressurization can result in equipment rupture and serious
injury.
• Open a valve to relieve the ﬂuid expansion during heating.
• Replace hoses proactively at regular intervals based on your operating conditions.
PRESSURIZED ALUMINUM PARTS HAZARD

Use of ﬂuids that are incompatible with aluminum in pressurized equipment can cause serious
chemical reaction and equipment rupture. Failure to follow this warning can result in death,
serious injury, or property damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon
solvents or ﬂuids containing such solvents.
• Many other ﬂuids may contain chemicals that can react with aluminum. Contact your material
supplier for compatibility.
PLASTIC PARTS CLEANING SOLVENT HAZARD

Many solvents can degrade plastic parts and cause them to fail, which could cause serious
injury or property damage.
• Use only compatible water-based solvents to clean plastic structural or pressure-containing
parts.
• See
in this and all other equipment instruction manuals. Read ﬂuid and
solvent manufacturer’s MSDSs and recommendations.
Technical Data

332637C

Warnings

WARNING
EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the inﬂuence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated
system component. See
in all equipment manuals.
• Use ﬂuids and solvents that are compatible with equipment wetted parts. See Technical Data
in all equipment manuals. Read ﬂuid and solvent manufacturer’s warnings. For complete
information about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the
when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modiﬁcations may void agency approvals
and create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from trafﬁc areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
Technical Data

Pressure Relief Procedure

332637C

Warnings

WARNING
BATTERY HAZARD

The battery may leak, explode, cause burns, or cause an explosion if mishandled.
• Only use the battery type speciﬁed for use with the equipment. See
.
• Battery maintenance must only be performed or supervised by personnel knowledgeable of
batteries and the required precautions. Keep unauthorized personnel away from battery.
• When replacing the battery, use the same lead-acid automotive battery, with 800 CCA
minimum, speciﬁed for use with the equipment. See
.
• Do not dispose of battery in ﬁre. The battery is capable of exploding.
• Follow local ordinances and/or regulations for disposal.
• Do not open or mutilate the battery. Released electrolyte has been known to be harmful to
the skin and eyes and to be toxic.
• Remove watches, rings, or other metal objects.
• Only use tools with insulated handles. Do not lay tools or metal parts on top of battery.
Technical Data

Technical Data

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate ﬁngers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing
equipment, follow the
and disconnect all power sources.
Pressure Relief Procedure

332637C

Warnings

WARNING
ENTAGLEMENT HAZARD

Rotating parts can cause serious injury.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Do not wear loose clothing, jewelry or long hair while operating equipment.
• Equipment can start without warning. Before checking, moving, or servicing equipment,
follow the
and disconnect all power sources.
Pressure Relief Procedure

BURN HAZARD

Equipment surfaces and ﬂuid that is heated can become very hot during operation. To avoid
severe burns:
• Do not touch hot ﬂuid or equipment.
CALIFORNIA PROPOSITION 65

The engine exhaust from this product contains a chemical known to the State of California to
cause cancer, birth defects or other reproductive harm.

332637C

Important Isocyanate Information

Important Isocyanate Information
Isocyanates (ISO) are catalysts used in two component materials.
Isocyanate Conditions

Spraying or dispensing materials containing
isocyanates creates potentially harmful mists,
vapors, and atomized particulates.
Read material manufacturer’s warnings and
material MSDS to know speciﬁc hazards and
precautions related to isocyanates.
Prevent inhalation of isocyanate mists, vapors,
and atomized particulates by providing sufﬁcient
ventilation in the work area. If sufﬁcient ventilation
is not available, a supplied-air respirator is required
for everyone in the work area.
To prevent contact with isocyanates, appropriate
personal protective equipment, including
chemically impermeable gloves, boots, aprons,
and goggles, is also required for everyone in the
work area.
Material Self-Ignition

Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings
and material MSDS.

332637C

Keep Components A and B Separate

Cross-contamination can result in cured
material in ﬂuid lines which could cause serious
injury or damage equipment. To prevent
cross-contamination:
•
interchange component A and component
B wetted parts.
• Never use solvent on one side if it has been
contaminated from the other side.
Never

Moisture Sensitivity of Isocyanates

Exposure to moisture (such as humidity) will cause
ISO to partially cure; forming small, hard, abrasive
crystals, which become suspended in the ﬂuid.
Eventually a ﬁlm will form on the surface and the ISO
will begin to gel, increasing in viscosity
NOTICE

Partially cured ISO will reduce performance and
the life of all wetted parts.
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere.
store ISO in an open container.
• Keep the ISO pump wet cup or reservoir (if
installed) ﬁlled with appropriate lubricant. The
lubricant creates a barrier between the ISO and
the atmosphere.
• Use only moisture-proof hoses compatible with
ISO.
• Never use reclaimed solvents, which may
contain moisture. Always keep solvent
containers closed when not in use.
• Always lubricate threaded parts with an
appropriate lubricant when reassembling.
Never

Important Isocyanate Information

Foam Resins with 245 fa Blowing
Agents

Some foam blowing agents will froth at temperatures
above 90°F (33°C) when not under pressure,
especially if agitated. To reduce frothing, minimize
preheating in a circulation system.

Changing Materials
NOTICE

Changing the material types used in your
equipment requires special attention to avoid
equipment damage and downtime.
• When changing materials, ﬂush the equipment
multiple times to ensure it is thoroughly clean.
• Always clean the ﬂuid inlet strainers after
ﬂushing.
• Check with your material manufacturer for
chemical compatibility.
• When changing between epoxies and urethanes
or polyureas, disassemble and clean all ﬂuid
components and change hoses. Epoxies often
have amines on the B (hardener) side. Polyureas
often have amines on the B (resin) side.

332637C

Models

Models
Reactor 2 E-30i Elite

All base systems include ﬂuid inlet pressure and temperature sensors and Graco InSite™. For part numbers,
see Accessories, page 13
Model
Base Machine
Maximum Fluid
Working Pressure
psi (MPa, bar)
Approximate Output
per Cycle (A+B) gal.
(liter)
Max Flow Rate lb/min
(kg/min)
Total System Load †
(Watts)
Voltage (phase)
Available Auxiliary
Current at Volts, 60
Hz*

E-30i

No Air Compressor/Dryer
E-30i with heat

E-30i

With

Air Compressor/Dryer
E-30i with heat

272079

272080

272089

272090

2000 (13.8, 138)

0.0272 (0.1034)

30 (13.5)

7,400

11,600

13,500

17,700

240 VAC (1)
52 Amps (240)

240 VAC (1)
35 Amps (240)

240 VAC (1)
22 Amps (240)
9 Amps (120)

240 VAC (1)
5 Amps (240)
9 Amps (120)

Fusion AP Package 

AP2079

AP2080

AP2089

AP2090

(Gun Part No.)

(246102)

CS2079

CS2080

CS2089

CS2090

(CS02RD)

P22079

P22080

P22089

P22090

(GCP2R2)

24K240

24Y240

Fusion CS Package 
(Gun Part No.)

Probler P2 Package 
(Gun Part No.)

Heated Hose
50 ft (15 m)
Heated Whip Hose
10 ft (3 m)


Total system watts used by system, based on
maximum heated hose length of 310 ft (94.5 m)
for each unit.

Full load amps available for auxiliary equipment
when all bare-system components are operating at
maximum capabilities. Available auxiliary current
is based on 310 ft (94.5 m) of heated hose. An
additional 3.0 amps (240 VAC) of auxiliary current
is available for each 50 ft (15.2 m) section of
heated hose that is not used.
Auxiliary current at 120 VAC is available on line 1
(circuit breaker pin 2), line 2 current at 120 VAC is
used by the air dryer (circuit breaker pin 4).

332637C



Available auxiliary current will be less when the
engine is de-rated for site altitude. Reduce the
Available Auxiliary Current in the chart by 2.5
Amps (240 VAC) per 1000 ft (300 m) elevation
increments. If the available auxiliary current is
less than zero, the system conﬁguration may not
support the full load at that altitude.



Includes Complete Air Compressor/Dryer Kit
24U176.
See Approvals, page 13.



Packages include gun, heated hose, and whip
hose.

Models

Reactor 2 E-XP2i Elite

All base systems include ﬂuid inlet pressure and temperature sensors and Graco InSite™. For part numbers,
see Accessories, page 13
Model

No Air Compressor/Dryer
E-XP2i with heat

Air Compressor/Dryer
E-XP2i with heat

272081

272091

3500 (24.1, 241)

0.0272 (0.1034)

30 (13.5)
11,600

30 (13.5)
17,700

240 VAC (1)
35 Amps (240)

240 VAC (1)
5 Amps (240)
9 Amps (120)

Fusion AP Package 

AP2081

AP2091

(Gun Part No.)

(246101)

P22081
(GCP2R1)
24Y241

P22091

(Gun Part No.)

24Y241

246055

Base Machine
Maximum Fluid Working Pressure psi
(MPa, bar)
Approximate Output per Cycle (A+B)
gal. (liter)
Max Flow Rate lb/min (kg/min)
Total System Load † (Watts)
Voltage (phase)
Available Auxiliary Current at Volts, 60
Hz*

Probler P2 Package 
Heated Hose
50 ft (15 m)
Heated Whip Hose
10 ft (3 m)


Total system watts used by system, based on
maximum heated hose length of 310 ft (94.5 m)
for each unit.

Full load amps available for auxiliary equipment
when all bare-system components are operating
at maximum capabilities. Available auxiliary
current is based on 310 ft (94.5 m) of heated hose.
An additional 3.0 amps (240 VAC) of auxiliary
current is available for each 50 ft (15.2 m) section
of heated hose that is not used.
Auxiliary current at 120 VAC is available on line 1
(circuit breaker pin 2), line 2 current at 120 VAC is
used by the air dryer (circuit breaker pin 4).

With

(GCP2R1)





Includes Complete Air Compressor/Dryer Kit
24U176.
See Approvals, page 13.



Packages include gun, heated hose, and whip
hose.

332637C

Approvals

Note

Intertek approvals apply to proportioning systems
without hoses.
Model

272079
272089

Heated hoses provided with a system or sold
individually are not approved by Intertek.

Accessories

Proportioning System Approvals:
Kit Number

15M483
15V551
24K207
9902471

Conforms to ANSI/UL Std. 73
Certiﬁed to CAN/CSA Std.
C22.2 No. 68

272080
272081
272090
272091

Cables

121006
9902471

Conforms to ANSI/UL Std. 499
Certiﬁed to CAN/CSA Std.
C22.2 No. 88

332637C

24K333
24K336
24K337
24L911
24M174
24U174
24U176
24U177
24N365
24N449

Description

Remote Display Module Protective
Covers (10 pack)
ADM Protective Covers (10 pack)
Fluid Temperature Sensor (FTS)
with RTD
Fuel Line and Cable Extension Kit
Hose Rack
Light Tower Kit
Pallet Support Kit
Drum Level Sticks
Remote Display Module Kit
Complete Air Compressor Kit
Feed Pump Shutdown Kit
150 ft (45 m) cable (for remote
display module)
RTD Test Cables (to aide resistance
measurements)
50 ft (15 m) CAN cable (for remote
display module)

Supplied Manuals

Related Manuals

The following manuals are shipped with the Reactor.
Refer to these manuals for detailed equipment
information.
Manuals are also available at www.graco.com.

The following manuals are for accessories used with
the Reactor.

Manual

332636
333093

Description

Reactor 2 Elite Integrated
Proportioning System, Operation
Reactor 2 Elite Integrated
Proportioning System, Startup
Instructions
333094
Reactor 2 Elite Integrated
Proportioning System, Shutdown
Instructions
SEBU8311– Perkins® Engine, Repair-Parts
02
Access at www.perkins.com. Go

to Service and Support/manuals.
Select engine family and type code
“GN”.

Contact Perkins for engine warranty
and service.

Mecc Alte Self-Regulating Alternator
Series NPE, Repair-Parts
Access at www.meccalte.com.
Select “meccalte” logo / Download
/ Instruction Manuals. Select NPE
instruction manual on page 5. Go to
Support and enter serial number for
Parts List and Help Videos.

ST
15825–00
33227482

Contact Mecc Alte for warranty and
service

Air Compressor, Operation/Maintenance & Parts list.

Access at www.hydrovaneproducts.com. Go to Warranty & Service
tab and select “contact us” to
request manuals.

Refrigerated Air Dryer, Instruction
manual
Access from Service
Department (724) 746–1100 or
www.spx.com/en/hankison.

Component Manuals in English:

Manuals are available at www.graco.com.
System Manuals

332636

Reactor 2 E-30i and E-XP2i, Operation

Displacement Pump Manual

309577

Electric Reactor Displacement Pump,
Repair-Parts
Heated Hose, Instructions-Parts
Circulation and Return Tube Kit,
Instructions-Parts
Feed Pump Kits, Instructions-Parts
Feed Pump Air Supply Kit,
Instructions-Parts
Fusion ™ AP Gun
Fusion ™ CS Gun
Probler® P2 Gun

Feed System Manuals

309572
309852
309815
309827

Spray Gun Manuals

309550
312666
313213

Accessory Manuals

332733
332738
332740
3A2574
3A1903
3A1904
3A1905
3A1906

Air Compressor and Air Dryer Kit,
Instructions-Parts
Booster Heat Retroﬁt Kit,
Instructions-Parts
Remote Display Module,
Instructions-Parts
Pallet Support Kit, Instructions-Parts
Hose Rack, Instructions-Parts
Fuel Tank/Battery Move Kit,
Instructions-Parts
Feed Pump Shutdown Kit,
Instructions-Parts
Light Tower Kit, Instructions-Parts

332637C

Troubleshooting

Troubleshoot Errors

There are three types of errors that can occur. Errors
are indicated on the display as well as by the light
2. The QR code screen will be displayed. Scan
tower (optional).
the QR code with your mobile device to be sent
directly to online troubleshooting for the active
error code. Otherwise, manually navigate to
A parameter critical to
help.graco.com and search for the active error.
the process has reached
a level requiring the
system to stop. The
alarm needs to be
addressed immediately.
A parameter critical
to the process has
reached a level requiring
attention, but not
sufﬁcient enough to
stop the system at this
time.
A parameter that is
Note
not immediately critical
to the process. The
Press or to return to the
advisory needs attention
previously displayed screen.
to prevent more serious
issues in the future.
3. If no internet connection is available, see Error
Code Troubleshooting in the system repair
See Error Codes, page 16 see for causes and
manual for causes and solutions for each error
solutions to each error code.
code.
To troubleshoot the error:
1. Press the soft key next to “Help With This Error”
for help with the active error.
Error

Description

Alarms

Deviations

Advisories

332637C

Troubleshooting

Error Codes
Error

Location

A1NM MCM

Type

Description

Low Motor Current

Cause

Loose/broken
connection.
Bad Motor.

A4DA

Heater A

High Current A

Short circuit in
heater wiring.
Bad heater.

A4DB

Heater B

High Current B

Short circuit in
heater wiring.
Bad heater.

High Current Hose

Short circuit in
hose wiring.

A4DH Hose

Solution

Check for loose wire
terminations at MCM motor
connector.
Disconnect motor output
connector from MCM.
Conﬁrm less than 8 ohms
resistance between each
pair of motor power leads
(M1 to M2, M1 to M3, M2 to
M3). If any readings greater
than 8 ohms, check motor
wiring for damage and/or
loose terminations.
Check wiring for touching
wires.
Conﬁrm resistance of
heater. Heater resistance
should be 23-26 Ω. If out of
tolerance, replace heater.
Check wiring for touching
wires.
Conﬁrm resistance of
heater. Heater resistance
should be 23-26 Ω. If out of
tolerance, replace heater.
Check continuity of
transformer windings.
Normal readings are about
0.2Ω on both primary and
secondary. If reading is 0Ω
replace transformer.
Check for shorts between
the primary winding and the
support frame or enclosure.

332637C

Troubleshooting

Error

Location

A7DA

Heater A

A7DB

Heater B

A4NM MCM

A7DH Hose
A8DA

Heater A

A8DB

Heater B

A8DH Hose

332637C

Type

Description

Cause

High Motor Current Short circuit of
motor wiring.

Solution

Check wiring to the motor
to ensure no bare wires are
touching and that no wires
are shorted to ground.
Motor will not
Remove pump gear
rotate.
housings from motor
and check that motor shaft
rotates freely in direction
indicated on motor housing.
Damaged gear Check pump gear trains
train.
for damage and repair or
replace as necessary.
Chemical pump is Repair or replace chemical
stuck.
pump.
Unexpected Current Shorted TCM
If error cannot be cleared
A
or regenerates consistently,
replace module.
Unexpected Current Shorted TCM
If error cannot be cleared
B
or regenerates consistently,
replace module.
Unexpected Current Shorted TCM
If error cannot be cleared
Hose
or regenerates consistently,
replace module.
Tripped circuit
Visually check circuit
No Current A
breaker.
breaker for a tripped
condition.
Loose/broken
Check heater wiring for
connection.
loose wires.
Tripped circuit
Visually check circuit
No Current B
breaker.
breaker for a tripped
condition.
Loose/broken
Check heater wiring for
connection.
loose wires.
Tripped circuit
Visually check circuit
No Current Hose
breaker.
breaker for a tripped
condition.
Loose/broken
Check heater wiring for
connection.
loose wires.

Troubleshooting

Error

Location

CACM MCM

Type

Description

MCM Communication Error

Cause

Module does not
have software.

Solution

332637C

Troubleshooting

Error

Location

CACT TCM

Type

Description

TCM Communication Module does not
have software.
Error

DADX MCM

Pump Runaway

DE0X

Cycle Switch Error

MCM

EAUX ADM

332637C

Cause

USB Busy

Solution

Insert a system token into
the ADM module and cycle
the power. Wait until the
upload is complete before
removing the token.
No 24 VDC supply Green light on each module
to module.
should be lit. If green light is
not lit, check to make sure
each CAN cable connection
is tight. Verify the power
supply is outputting 24
VDC. If not, check power
supply wiring. If wiring is
okay, replace the power
supply.
Loose or broken Check the CAN cables
CAN cable.
running between GCA
modules and tighten of
needed. If the problem
still persists move each
cable around the connector
and watch the ﬂashing
yellow light on the GCA
modules. If the yellow light
stops ﬂashing, replace the
CAN cable.
Flow rate is too Mix chamber too large for
large.
system selected. Use mix
chamber rated for system.
Ensure the system has
chemical and the feed
pumps are operating
correctly.
No material in pumps.
Verify pumps are supplying
chemical. If necessary,
replace or reﬁll drums.
Inlet ball valves are closed.
Open ball valves.
Faulty or missing Check wiring between cycle
cycle switch.
switch and MCM.
Missing or out of Check presence and
place cycle switch position of cycle switch
magnet on output crank
magnet.
arm.
Do not remove USB drive
USB drive has
until download/upload
been inserted to
is complete.
the ADM.
19

Troubleshooting

Error

Location

Description

Cause

EVUX ADM

USB disabled

USB
download/uploads
are disabled.

F9DX

High Pressure/Flow Mix chamber is
Cutback
too large for set
pressure.

EVCH ADM

MCM

Type

Manual Hose Mode Manual hose mode
Enabled
has been enabled
in System Setup
screen.

H1MA Heater A

Low Frequency A

Line frequency is
below 55 Hz.

H1MB Heater B

Low Frequency B

Line frequency is
below 55 Hz.

H1MH Hose

Low Frequency Hose Line frequency is
below 55 Hz.

Solution

Install a functioning ﬂuid
temperature sensor (FTS)
on the hose. Manual hose
mode will automatically turn
off.
Enable USB download/uploads on the Advanced
Setup screen before inserting a USB drive.
Reference the pressure
ﬂow curves and select a tip
size that is the correct size
for the set pressure.
Check frequency. If out
of tolerance, see supplied
120/240V alternator manual
for repair instructions.
Check frequency. If out
of tolerance, see supplied
120/240V alternator manual
for repair instructions.
Check frequency. If out
of tolerance, see supplied
120/240V alternator manual
for repair instructions.

332637C

Troubleshooting

Error

Location

H4MA Heater A

Type

Description

High Frequency A

H4MB Heater B

High Frequency B

H4MH Hose

High Frequency
Hose

K8NM MCM

Locked Rotor Motor

L1AX

ADM

Low Chemical Level
A

L1BX

ADM

Low Chemical Level
B

MMUX USB

Maintenance Due USB

332637C

Cause

Solution

Line frequency is Check frequency. If out
above 65 Hz.
of tolerance, see supplied
120/240V alternator manual
for repair instructions.
Line frequency is Check frequency. If out
above 65 Hz.
of tolerance, see supplied
120/240V alternator manual
for repair instructions.
Line frequency is Check frequency. If out
above 65 Hz.
of tolerance, see supplied
120/240V alternator manual
for repair instructions.
Motor will not
Remove pump gear
rotate.
housings from motor
and check that motor shaft
rotates freely in direction
indicated on motor housing.
Damaged gear Check motor/pump gear
train.
trains for damage and repair
or replace as necessary.
Chemical pump is Repair or replace chemical
pump.
stuck.
Low material level. Reﬁll material and update
drum level on ADM
Maintenance screen.
Alarm can be disabled on
the System Setup screen.
Low material level. Reﬁll material and update
drum level on ADM
Maintenance screen.
Alarm can be disabled on
the System Setup screen.
USB logs have Insert a USB drive into the
reached a level ADM and download all logs.
where data loss
will occur if logs are
not downloaded.

Troubleshooting

Error

P0AX

Location

MCM

Type

Description

Cause

Pressure Imbalance Pressure
A High
difference between
A and B material
is greater than the
deﬁned value.
Pressure
imbalance is
deﬁned too low.

Solution

Ensure material ﬂow is
equally restricted on both
material lines.

332637C

Troubleshooting

Error

P0BX

Location

MCM

P1FA

MCM

P1FB

MCM

332637C

Type

Description

Cause

Pressure Imbalance Pressure
B High
difference between
A and B material
is greater than the
deﬁned value.
Pressure
imbalance is
deﬁned too low.

Solution

Ensure material ﬂow is
equally restricted on both
material lines.

Ensure that the pressure
imbalance value, on the
System Setup screen, is at
an acceptable maximum
pressure to prevent
unnecessary alarms and
abort dispenses.
Out of material. Fill tanks with material
Fluid leaking from Check if heater
heater inlet rupture and PRESSURE
RELIEF/SPRAY valve are
disk.
plugged. Clear. Replace
rupture disk. Do not replace
with a pipe plug.
Feed system
Check feed pump and
defective.
hoses for blockage. Check
that feed pumps have
correct air pressure.
Ensure that inlet pressure
Low Inlet Pressure A Inlet pressure
lower than deﬁned to the pump is sufﬁcient.
value.
Value deﬁned too Ensure that the low
pressure alarm level
high.
deﬁned on the System
Setup screen is acceptable.
Ensure that inlet pressure
Low Inlet Pressure B Inlet pressure
lower than deﬁned to the pump is sufﬁcient.
value.
Value deﬁned too Ensure that the low
pressure alarm level
high.
deﬁned on the System
Setup screen is acceptable.

Troubleshooting

Error

P2FA

Location

MCM

P2FB

MCM

P4AX

MCM

P4BX

MCM

Type

Description

Cause

Low Inlet Pressure A Inlet pressure
lower than deﬁned
value.
Value deﬁned too
high.

Solution

Ensure that inlet pressure
to the pump is sufﬁcient.

Ensure that the low
pressure alarm level
deﬁned on the System
Setup screen is acceptable.
Low Inlet Pressure B Inlet pressure
Ensure that inlet pressure
lower than deﬁned to the pump is sufﬁcient.
value.
Value deﬁned too Ensure that the low
pressure alarm level
high.
deﬁned on the System
Setup screen is acceptable.
Pressure in the hose and
High Pressure A
System
pressurized before pumps will increase as the
allowing heat to system heats up. Turn on
heat and allow all zones
reach setpoint.
to reach the temperature
setpoint before turning on
the pumps.
Bad pressure
Verify the ADM pressure
transducer.
reading and the analog
guages at the manifold.
E-XP2i system
Alarm level is lower for
conﬁgured as
E-30i than for E-XP2i.
E-30i.
Ensure dial on MCM is set
to position "1" for E-XP2i.
Pressure in the hose and
High Pressure B
System
pressurized before pumps will increase as the
allowing heat to system heats up. Turn on
heat and allow all zones
reach setpoint.
to reach the temperature
setpoint before turning on
the pumps.
Bad pressure
Verify the ADM pressure
transducer.
reading and the analog
guages at the manifold.
E-XP2i system
Alarm level is lower for
conﬁgured as
E-30i than for E-XP2i.
E-30i.
Ensure dial on MCM is set
to position "1" for E-XP2i.

332637C

Troubleshooting

Error

P6AX

Location

MCM

Type

Description

Pressure Sensor
Error A

Cause

Loose/bad
connection.
Bad sensor.

P6BX

MCM

Pressure Sensor
Error B

Loose/bad
connection.
Bad sensor.

P6FA

MCM

Pressure Sensor
Error Inlet A

Inlet sensors not
installed.
Loose/bad
connection.
Bad sensor.

332637C

Solution

Check to ensure the
pressure transducer is
properly installed and
all wires are properly
connected.
Check if the error follows
the transducer. Disconnect
transducer cables from
the MCM (connectors 6
and 7). Reverse A and B
connections and check if
the errors follows. If the
error follows the transducer,
replace the pressure
transducer.
Check to ensure the
pressure transducer is
properly installed and
all wires are properly
connected.
Check if the error follows
the transducer. Disconnect
transducer cables from
the MCM (connectors 6
and 7). Reverse A and B
connections and check if
the errors follows. If the
error follows the transducer,
replace the pressure
transducer.
If inlet sensors are not
installed, inlet sensors
should be disabled on the
System Setup screen.
Check to ensure inlet
sensor is properly installed
and all wires are properly
connected.
Check if the error follows
the inlet sensor. Disconnect
inlet sensor cables from
the MCM (connectors 8
and 9). Reverse A and B
connections and check if
the errors follows. If the
error follows the sensor,
replace the inlet sensor.

Troubleshooting

Error

Location

P6FB

MCM

P7AX

MCM

Type

Description

Cause

Inlet sensors not
installed.

Solution

If inlet sensors are not
installed, inlet sensors
should be disabled on the
System Setup screen.
Loose/bad
Check to ensure inlet
connection.
sensor is properly installed
and all wires are properly
connected.
Bad sensor.
Check if the error follows
the inlet sensor. Disconnect
inlet sensor cables from
the MCM (connectors 8
and 9). Reverse A and B
connections and check if
the errors follows. If the
error follows the sensor,
replace the inlet sensor.
Pressure Imbalance Pressure
Ensure material ﬂow is
A High
difference between equally restricted on both
A and B material material lines.
is greater than the
deﬁned value.
Ensure that the pressure
Pressure
imbalance value, on the
imbalance is
deﬁned too low. System Setup screen, is at
an acceptable maximum
pressure to prevent
unnecessary alarms and
abort dispenses.
Out of material. Fill tanks with material
Fluid leaking from Check if heater
heater inlet rupture and PRESSURE
RELIEF/SPRAY valve are
disk.
plugged. Clear. Replace
rupture disk. Do not replace
with a pipe plug.
Feed system
Check feed pump and
defective.
hoses for blockage. Check
that feed pumps have
correct air pressure.
Pressure Sensor
Error Inlet B

332637C

Troubleshooting

Error

P7BX

T1DE

332637C

Location

MCM

Engine
Heat
Exchanger

Type

Description

Cause

Pressure Imbalance Pressure
B High
difference between
A and B material
is greater than the
deﬁned value.
Pressure
imbalance is
deﬁned too low.

Low Temperature
Coolant Outlet

Solution

Ensure material ﬂow is
equally restricted on both
material lines.

Troubleshooting

Error

T2AE

Location

Heat Ex. A

Type

Description

Low Temperature
Heat Exchanger A

Cause

Solution

332637C

Troubleshooting

Error

Location

T2DA

Heater A

T2BE

332637C

Heat Ex. B

Type

Description

Low Temperature
Heat Exchanger B

Cause

Solution

Coolant circulation Check for 240 VAC on
pump not working. pump. If there is the correct
voltage, replace circulation
pump.
Air lock in pump Check for coolant ﬂow in
circulation.
sight glass.
No voltage to coil Turn on the manual valve
of valve.
switch (MV), on the load
center, to manually turn on
the solenoids and see if the
temperature rises. If not,
check volatge output on J6
connectoron the load center
and ensure the LEDs are
on. Follow Load Center
Diagnostic instructions in
system repair manual. If
necessary, replace the load
center board. If voltage
is present, measure the
resistance of the coil, it
should be 12.5 Ω. If coil
is open replace coil. If
voltage is present, test
the coil with screwdriver.
The screwdriver should
magnetically stick inside
the coil. If the screwdriver
sticks, then the coil is
good. Replace the plunger
on valve or replace the
complete valve assembly.
Low Temperature A Flow is too high at Use a smaller mix chamber
current setpoint. that is rated for the unit
in use. If recirculating,
decrease ﬂow or decrease
temperature setpoint.
Bad RTD or bad Swap A and B heater output
RTD placement cables and RTD cables and
against heater.
see if issue follows. If so,
replace RTD.
Bad heater.
Conﬁrm resistance of heater
is 23-26.5 Ω. Replace if
OL/open loop.

Troubleshooting

Error

Location

T2DB

Heater B

T2DE

Heat
Exchanger

T2DH

Hose

T2FA

MCM

T2FB

MCM

Type

Description

Cause

Solution

Low Temperature B Flow is too high at Use a smaller mix chamber
current setpoint. that is rated for the unit
in use. If recirculating,
decrease ﬂow or decrease
temperature setpoint.
Bad RTD or bad Swap A and B heater output
RTD placement cables and RTD cables and
against heater.
see if issue follows. If so,
replace RTD.
Bad heater.
Conﬁrm resistance of heater
is 23-26.5 Ω. Replace if
OL/open loop.
Low Temperature Radiator fan will Replace fan relay.
Coolant Outlet
not stop.
Engine thermostat Replace thermostat.
is stuck closed.
Low Temperature Flow is too high at Use a smaller mix chamber
Hose
current setpoint. that is rated for the unit
in use. If recirculating,
decrease ﬂow or decrease
temperature setpoint.
Cold chemical in Recirculate heated
unheated portion chemical back to drum
of system passed in cold conditions before
startup.
hose FTS at
startup.
Low Temperature Inlet ﬂuid
Recirculate ﬂuid through
Inlet A
temperature is
heaters until inlet ﬂuid
below the deﬁned temperature is above
level.
deﬁned error level.
Increase the low
temperature deviation
level on the System Setup
screen.
Low Temperature Inlet ﬂuid
Recirculate ﬂuid through
Inlet B
temperature is
heaters until inlet ﬂuid
below the deﬁned temperature is above
level.
deﬁned error level.
Increase the low
temperature deviation
level on the System Setup
screen.

332637C

Troubleshooting

Error

Location

Type

Description

T3CH

Hose

T3CT

TCM

TCM Cutback

T3NM MCM

MCM Cutback

T4AE

High Temperature
Heat Exchanger A

332637C

Heat Ex. A

Hose Cutback

Cause

Hose current has
been reduced
because hose
has been drawing
current for an
extended period.

Solution

Hose setpoint higher than A
and B setpoints. Decrease
hose setpoint.
Hose FTS is in a colder
environment than the rest
of the hose. Expose FTS to
the same environment as
the rest of the hose.
High ambient
Ensure ambient
temperature.
temperature is below
120°F(48°C) before using
the system.
Enclosure fan not Ensure fan in electrical
operating.
enclosure is spinning. If it
is not, check fan wiring or
replace fan.
Module fan not If a TCM fan error (WMI0)
operating.
has occurred, fan inside
the module is not working
properly. Check TCM fan
for debris and clear with
forced air if necessary.
Motor is operating The system is running at a
lower setpoint to preserve
outside of the
motor life. Run the system
pressure ﬂow
at a lower duty cycle or with
curve.
a smaller mix chamber.
Manual valve
Open cabinet cover and
switch (MV) on turn switch to the OFF
load center is in the position.
ON position.
A or B side control Debris in valve diaphragm
valve solenoid is or plunger preventing
stuck in the open spring-loaded closed
function. Disconnect
position.
connector from valve
solenoid cable. If
temperature does not
decrease, rebuild solenoid.
Short on load
If the blue and red LEDs are
center board.
on while heat is off, the load
center board is bad. See
Load Center Diagnostics in
the system repair manual.

Troubleshooting

Error

T4BE

Location

Heat Ex. B

Type

Description

High Temperature
Heat Exchanger B

T4CM MCM

High Temperature
MCM

T4CT

High Temperature
TCM

TCM

Cause

Manual valve
switch (MV) on
load center is in the
ON position.
A or B side control
valve solenoid is
stuck in the open
position.

Solution

Open cabinet cover and
turn switch to the OFF
position.

Debris in valve diaphragm
or plunger preventing
spring-loaded closed
function. Disconnect
connector from valve
solenoid cable. If
temperature does not
decrease, rebuild solenoid.
Short on load
If the blue and red LEDs are
center board.
on while heat is off, the load
center board is bad. See
Load Center Diagnostics in
the system repair manual.
J6 connector on Reconnect J6 connector
load center "Heat on load center in centered
Valves" location is location.
not centered.
High ambient
Ensure ambient
temperature.
temperature is below
120°F(48°C) before using
the system.
Enclosure fan not Ensure fan in electrical
operating.
enclosure is spinning. If it
is not, check fan wiring or
replace fan.
High ambient
Ensure ambient
temperature.
temperature is below
120°F(48°C) before using
the system.
Enclosure fan not Ensure fan in electrical
operating.
enclosure is spinning. If it
is not, check fan wiring or
replace fan.
Module fan not If a TCM fan error (WMI0)
operating.
has occurred, fan inside
the module is not working
properly. Check TCM fan
for debris and clear with
forced air if necessary.

332637C

Troubleshooting

Error

T4DA

Location

Heater A

T4DB

Heater B

T4DE

Heat
Exchanger

T4DH

Hose

332637C

Type

Description

Cause

High Temperature A Bad RTD or bad
RTD placement
against heater.

Solution

Swap A and B heater output
cables and RTD cables and
see if issue follows. If so,
replace RTD.
Use a smaller mix chamber
that is rated for the unit in
use.

Flow too high
for temperature
setpoint, causing
temperature
overshoots when
gun is de-triggered.
High Temperature B Bad RTD or bad Swap A and B heater output
RTD placement cables and RTD cables and
against heater.
see if issue follows. If so,
replace RTD.
Use a smaller mix chamber
Flow too high
for temperature that is rated for the unit in
setpoint, causing use.
temperature
overshoots when
gun is de-triggered.
High Temperature Broken fan.
Check fan relay (K4) and
Coolant Outlet
fuse (30 Amp ATO "F3") on
load center board. Replace
if needed.
Plugged radiatior. Replace if needed.
High ambient
Ensure ambient
temperature.
temperature is below
120°F(48°C) before using
the system.
Shade exposed hose from
High Temperature Hose portion
hot sun or expose FTS to
Hose
exposed to an
excessive heat same environment when
source, like hot at rest. Uncoil entire hose
before heating to avoid
sun or coiled
hose, can pass self-heating.
ﬂuid more than
27°F (15°C) over
hose temperature
setting to the FTS.
Setting the A or Increase hose setpoint
B setpoint much so it is closer to A and B
higher than hose setpoints.
setpoint can cause
ﬂuid more than
27°F (15°C) over
hose temperature
setting to reach the
FTS.
33

Troubleshooting

Error

Location

T4EA

Heater A

T4EB

Heater B

Type

Description

High Temperature
Switch A

High Temperature
Switch B

Cause

Solution

Heater was delivered too
much power, causing the
overtemperature switch to
open. RTD is not reading
properly. After the heater
cools down, replace RTD.
Switch closes and the error
can be cleared when the
heater temperature falls
below 190°F (87°C).
Broken or loose If heater is not actually
overtemperature over temperature, check
switch
all wiring and connections
cable/connection. between the TCM and the
overtemperature switches.
Overtemperature Replace overtemperature
switch failed in the switch.
open position.
Overtemperature Heater was delivered too
switch sensed a much power, causing the
ﬂuid temperature overtemperature switch to
open. RTD is not reading
above 230°F
properly. After the heater
(110°C).
cools down, replace RTD.
Switch closes and the error
can be cleared when the
heater temperature falls
below 190°F (87°C).
Broken or loose If heater is not actually
overtemperature over temperature, check
switch
all wiring and connections
cable/connection. between the TCM and the
overtemperature switches.
Overtemperature Replace overtemperature
switch failed in the switch.
open position.
Overtemperature
switch sensed a
ﬂuid temperature
above 230°F
(110°C).

332637C

Troubleshooting

Error

Location

T6AE

Heat Ex. A

Sensor Error Heat
Exchanger A

T6BE

Heat Ex. B

Sensor Error Heat
Exchanger B

T6DA

Heater A

Sensor Error A

T4NM MCM

332637C

Type

Description

High Temperature
Motor

Cause

Solution

Cooling fan is not Check to see that the motor
operating properly. fan is moving. Measure
voltage to fan. There should
be 24 VDC. If no voltage
is measured, check fan
wiring.If the fan has voltage
but is not moving, replace
fan. If necessary use an air
hose to blow out around the
fan housings and remove
any built-up debris.
Broken or loose Verify wiring between the
motor temperature motor temperature sensor
cable.
and the MCM.
High ambient
Ensure ambient
temperature.
temperature is below
120°F(48°C) before using
the system.
Bad electric motor. Replace electric motor.
Broken or loose Check all wiring and
RTD cable or
connection to RTD.
connection.
Bad RTD.
Switch the RTD with
another and see if the error
message follows the RTD.
Replace RTD if the error
follows the RTD.
Broken or loose Check all wiring and
RTD cable or
connection to RTD.
connection.
Bad RTD.
Switch the RTD with
another and see if the error
message follows the RTD.
Replace RTD if the error
follows the RTD.
Disconnected or Check all wiring and
loose RTD cable or connection to RTD.
connection.
Bad RTD.
Switch the RTD with
another and see if the error
message follows the RTD.
Replace RTD if the error
follows the RTD.

Troubleshooting

Error

Location

T6DB

Heater B

T6DE

Engine
Heat
Exchanger

T6DH

Hose

T6DT

TCM

Type

Description

Cause

Solution

Disconnected or Check all wiring and
loose RTD cable or connection to RTD.
connection.
Bad RTD.
Switch the RTD with
another and see if the error
message follows the RTD.
Replace RTD if the error
follows the RTD.
Sensor Error Coolant Disconnected or Check all wiring and
loose RTD cable or connection to RTD.
Outlet
connection.
Bad RTD.
Switch the RTD with
another and see if the error
message follows the RTD.
Replace RTD if the error
follows the RTD.
Sensor Error Hose Disconnected or Expose each hose RTD
shorted RTD cable connection to check and
in hose or bad FTS. retighten any loose connector. Measure hose RTD
cable and FTS continuity.
See Repair Heated Hose,
page 87. Order RTD Test
kit 24N365 for measurement. Disconnect hose
RTD and use manual hose
mode to ﬁnish job until
repair can be completed.
Sensor Error TCM Shorted RTD cable Expose each hose RTD
in hose or FTS. connection to check for
exposed and shorted RTD
wires. Measure hose RTD
cable and FTS continuity.
See Repair Heated Hose,
page 87. Order RTD Test
kit 24N365 for measurement. Disconnect hose
RTD and use manual hose
mode to ﬁnish job until
repair can be completed.
Shorted Heater A If the error still occurs with
or B RTD
the hose FTS unplugged,
one of the heater RTDs
is bad. Unplug the A or
B RTD from the TCM. If
unplugging an RTD ﬁxes
the T6DT error, replace the
RTD.
Sensor Error B

332637C

Troubleshooting

Error

T8AE

332637C

Location

Heat Ex. A

Type

Description

Cause

No Temperature
No coolant ﬂow.
Rise Heat Exchanger
A

Solution

Troubleshooting

Error

Location

T8DA

Heater A

T8BE

Heat Ex. B

Type

Description

Cause

No Temperature
No coolant ﬂow.
Rise Heat Exchanger
B

No Temperature
Rise A

Solution

Check coolant level.
Check for coolant ﬂow
in sight glass.Ensure that
circulation pump has 240
VAC. If not, replace the
circulation pump.
Low chemical
Chemical below 32°F(0°C)
supply
at startup. Recirculate cold
temperature.
chemical back to drum
in cold conditions before
spraying.
Ensure ambient
System stored
below 20°F(-7°C) temperature is above
20°F(-7°C) .
causing slow
coolant valve
operation.
Bad valvesolenoid. Turn on the manual valve
switch (MV), on the load
center, and see if the
valve shifts. If not replace
solenoid.
Bad load center. Red, blue, and green LEDs
should light up on load
center board. If not, replace
load center.
J6 connector on Reconnect J6 connector
load center "Heat on load center in centered
Valves" location is location.
not centered.
Bad heater rod. Measure resistance of
heater rod, should be 23-26
Ω. Replace if open.
Bad RTD or bad Swap A and B heater output
RTD placement cables and RTD cables and
see if issue follows. If so,
against heater.
replace RTD.
Bad valvesolenoid. Turn on the manual valve
switch (MV), on the load
center, and see if the
valve shifts. If not replace
solenoid.
Started spraying Wait until operating
temperature has been
before heater
reached operating reached before spraying or
recirculating.
temperature.

332637C

Troubleshooting

Error

Location

T8DH

Hose

T8DB

Heater B

Type

Description

No Temperature
Rise B

No Temperature
Rise Hose

V1CM MCM

Low Voltage MCM

V1IT

Low Voltage CAN

TCM

V1MA TCM

332637C

Low Voltage A

Cause

Bad heater rod.

Solution

Measure resistance of
heater rod, should be 23-26
Ω. Replace if open.
Bad RTD or bad Swap A and B heater output
RTD placement cables and RTD cables and
against heater.
see if issue follows. If so,
replace RTD.
Bad valve solenoid. Turn on the manual valve
switch (MV), on the load
center, and see if the
valve shifts. If not replace
solenoid.
Started spraying Wait until operating
temperature has been
before heater
reached operating reached before spraying or
recirculating.
temperature.
Started spraying Wait until operating
temperature has been
before heater
reached operating reached before spraying or
recirculating.
temperature.
Loose/bad
Check wiring for loose
connection or
connection or tripped circuit
tripped circuit
breaker.
breaker.
Low generator line Measure voltage across
voltage.
main power switch (CT01).
Voltage should measure
between 195 and 264 VAC.
Bad 24 VDC power Check voltage of power
supply.
supply. Voltage should
be 23-25 VDC. If out of
tolerance, replace power
supply.
Loose connection Check wiring for loose
or tripped circuit connection or tripped circuit
breaker.
breaker.
Low generator line Measure voltage across
voltage.
main power switch (CT01).
Voltage should measure
between 195 and 264 VAC.
High auxilary
Ensure compressor or
inrush current.
air drier are set up to be
continuous run and sized
according to the manual.

Troubleshooting

Error

Location

V1MB TCM

Type

Description

Low Voltage B

Cause

Loose connection
or tripped circuit
breaker.
Low generator line
voltage.
High auxilary
inrush current.

V1MH TCM

Low Voltage Hose

Loose connection
or tripped circuit
breaker.
Low generator line
voltage.
High auxilary
inrush current.

V2IT

TCM

Low Voltage CAN

Bad 24 VDC power
supply.

V3IT

TCM

High Voltage CAN

Bad 24 VDC power
supply.

V4CM MCM

High Voltage MCM

Incoming line
voltage is too high.

V4IT

High Voltage CAN

Bad 24 VDC power
supply.

TCM

Solution

Check wiring for loose
connection or tripped circuit
breaker.
Measure voltage across
main power switch (CT01).
Voltage should measure
between 195 and 264 VAC.
Ensure compressor or
air drier are set up to be
continuous run and sized
according to the manual.
Check wiring for loose
connection or tripped circuit
breaker.
Measure voltage across
main power switch (CT01).
Voltage should measure
between 195 and 264 VAC.
Ensure compressor or
air drier are set up to be
continuous run and sized
according to the manual.
Check voltage of power
supply. Voltage should
be 23-25 VDC. If out of
tolerance, replace power
supply.
Check voltage of power
supply. Voltage should
be 23-25 VDC. If out of
tolerance, replace power
supply.
Measure voltage across
main power switch (CT01).
Voltage should measure
between 195 and 264 VAC.
If voltage is too high, see
supplied alternator manual
for generator speciﬁcs and
repair.
Check voltage of power
supply. Voltage should
be 23-25 VDC. If out of
tolerance, replace power
supply.

332637C

Troubleshooting

Error

Location

V4MA TCM

V4MB TCM

V4MH TCM

WBC0 MCM
WMCE MCM
WMI0

TCM

WSUX USB
WXUD ADM
WXUU ADM

332637C

Type

Description

High Voltage A

Cause

Solution

Incoming line
Measure voltage across
voltage is too high. main power switch (CT01).
Voltage should measure
between 195 and 264 VAC.
If voltage is too high, see
supplied alternator manual
for generator speciﬁcs and
repair.
High Voltage B
Incoming line
Measure voltage across
voltage is too high. main power switch (CT01).
Voltage should measure
between 195 and 264 VAC.
If voltage is too high, see
supplied alternator manual
for generator speciﬁcs and
repair.
High Voltage Hose Incoming line
Measure voltage across
voltage is too high. main power switch (CT01).
Voltage should measure
between 195 and 264 VAC.
If voltage is too high, see
supplied alternator manual
for generator speciﬁcs and
repair.
Software Version Incorrect software Insert a system token into
the ADM module and cycle
Error
version.
the power. Wait until the
upload is complete before
removing the token.
Load Center Fault Bad connection Check connection and
between MCM and cables.
load center board.
Bad load center. Replace load center.
TCM Fan Error
Fan inside TCM Check for debris in the TCM
is not operating fan and clear with forced air
if necessary.
properly.
Inset a system token into
Conﬁguration Error A valid
conﬁguration ﬁle the ADM and cycle power.
USB
can't be found for Wait until the lights on the
USB port stop ﬂashing
the USB.
before removing token.
Backup and reformat the
USB Download Error Log download
failed.
USB drive. Retry download.
USB Upload Error Custom language Perform normal USB
ﬁle failed to upload. download and use the new
disptext.txt ﬁle to upload the
custom language.
41

Troubleshooting

System

See Supplied Manuals, page 14, for air compressor service or warranty contact information.

Before performing any troubleshooting procedures:
1. Relieve Pressure. See Pressure Relief Procedure, page 60.
2. Turn main power switch OFF.
3. Allow equipment to cool.
Problem

Cause

Reactor ADM does not turn on.

No power.

Electric motor does not operate.

Loose connections.
Tripped circuit breaker (CB02).

Electric motor runs erratically.

Shorted windings.
Failed motor bearings.

Solution

Turn main power switch ON.
Turn circuit breakers ON, see
Repair Circuit Breaker Module,
page 77.
Check circuit breaker (CB10). See
Repair Circuit Breaker Module,
page 77.
Check MCM connections. See
Electrical Schematics, page 154.
Reset breaker, see Repair Circuit
Breaker Module, page 77. Check
240VAC at output of breaker.
Replace motor, see
Repair Electric Motor, page 76.
Replace motor, see
Repair Electric Motor, page 76.

332637C

Troubleshooting

Problem

Electric motor cooling fan not
working.

Cause

Solution

Reset circuit breaker (CB03).
Check 240VAC at output of
breaker.
Loose wire.
Check. See
Electrical Schematics, page 154.
Fan blade obstructed.
Remove obstruction.
Defective fan.
Replace. See
Replace Motor Fan, page 82.
Pump output low.
Obstructed ﬂuid hose or gun; ﬂuid Open, clear; use hose with larger
hose ID too small.
ID.
Worn piston valve or intake valve See pump manual.
in displacement pump.
Pressure setpoint too high.
Reduce setpoint and output will
increase.
Fluid leak in pump packing nut Worn throat seals.
Replace. See pump manual.
area.
No pressure on one side.
Fluid leaking from heater inlet
Check if heater and PRESSURE
rupture disk (372).
RELIEF/SPRAY valve (SA or SB)
are plugged. Clear. Replace
rupture disk (372) with a new one;
do not replace with a pipe plug.
Air compressor does not start.
Tripped circuit breaker (CB04). Reset circuit breaker (CB04).
Not wired correctly.
See
Electrical Schematics, page 154.
Compressor starter overheated Let starter cool down for 2 minutes
from rapid multiple start and stop then press reset on the air
compressor electrical enclosure
procedures.
and start.
Air dryer cooling fan not running. Only runs after hot air ﬂow.
Normal operation.
Air dryer not draining water.
Power not turned on at dryer.
Turn dryer switch ON ( | ).
No air usage.
Check after air ﬂowing.

332637C

Tripped circuit breaker (CB03).

Troubleshooting

Coolant System

Problem
Proportioner Coolant Loop

Air bubbles in sight glass.

Heat exchanger coolant ﬂow
stopped. No ﬂow in sight glass.
Material slowly heats up.

Heat exchanger coolant in sight
glass is a milky color.
A or B material heats up slower
than the other.
A or B material cooling down
slower than the other.

Cause

Air trapped in heat exchanger
coolant.
Coolant hoses between the
proportioner coolant loop and
engine coolant loop were modiﬁed
and created a high point air pocket.
Proportioner coolant loop
expansion bottle is empty.
Circulation pump stopped running.
Bypass control valve does not
open.
Coolant ﬁlter plugged.

Solution

See Reﬁll Proportioner Coolant
Loop, page 68.
Ensure coolant hoses have a
constant rise in elevation.

See Reﬁll Proportioner Coolant
Loop, page 68.
Check circuit breaker. Check
voltage.
Repair or replace valve. See
Replace Control Valve, page 94.
Clean or replace ﬁlter in ﬁlter
housing, see Repair Filter Housing
Filter, page 96 and order replacement ﬁlter kit 24T028.
A and B control valves are not Repair or replace valve. See
opening fully.
Replace Control Valve, page 94.
System stored below 20°F(-7°C). Ensure system ambient
temperature is above 20°F(-7°C).
Possible material leaking into
Drain Proportioner coolant loop.
coolant.
See Drain Coolant, page 66.
Check for pressurized material
leaks.
Control valve opening too slow. Repair or replace valve. See
Replace Control Valve, page 94.
System stored below 20°F(-7°C). Ensure system ambient
temperature is above 20°F(-7°C).
Control valve coil failed.
Repair or replace valve coil. See
Replace Control Valve, page 94.
Control valve coil not allowing
Repair or replace valve coil. See
valve to normally close.
Replace Control Valve, page 94.
Control valve stuck in open
Repair valve. See
position.
Replace Control Valve, page 94.
Bad load center.
Replace the load
center board. See
Replace Load Center, page 80.

332637C

Troubleshooting

Problem
Engine Coolant Loop

Cause

Engine coolant does not reach full Radiator fan does not shut off.
temperature.
Radiator core becoming plugged.
Engine thermostat not opening.
Engine temperature normal, but Coolant level is low in expansion
heat exchanger temperature is low bottle.
or slowly increases.
No coolant ﬂow in engine coolant
loop.
Heat exchanger in the engine
coolant loop is plugged.
Expansion bottle levels are not Radiator or heat exchanger bottle
rising when coolant is heating.
cap not opening.
Coolant level in engine coolant Expansion bottle cap and radiator
expansion bottle rises too high cap are switched.
and too fast.
Spring loaded gasket inside
radiator cap does not seal.
Expansion bottle cap and radiator
Coolant level in proportioner
coolant expansion bottle does not cap are switched.
rise when hot.
Expansion bottle cap stuck open.
Coolant level in proportioner
coolant expansion bottle rises too
high and too fast.
Coolant level dropping in overﬂow Cap not fully tightened.
bottle but no visible leaks.

332637C

Solution

Check fan relay. Check fan wiring.
Replace radiator. See
Remove Radiator, page 100.
Replace engine thermostat.
Reﬁll Engine Coolant Loop, page
69.
Replace heat exchanger. See
Replace Heat Exchangers, page
91.
Replace cap.
Switch radiator caps. Radiator cap
is marked 16 lbs and expansion
bottle is marked 8 lbs.
Replace radiator cap.
Switch radiator caps. Radiator cap
is marked 16 lbs and expansion
bottle is marked 8 lbs.
Replace expansion bottle cap.
Push down and tighten cap past
safety latch position.

Troubleshooting

Hose Heat System

Before performing any troubleshooting procedures:
1. Relieve Pressure. See Pressure Relief Procedure, page 60.
2. Turn main power switch OFF.
3. Allow equipment to cool.
Problem

Hose heats but heats slower
than usual or it does not reach
temperature.
Hose does not maintain
temperature while spraying.

Hose temperature exceeds
setpoint.

Cause

Solution

Ambient temperature is too cold. Use auxiliary hose heat system.
FTS failed or not installed correctly. Check FTS, see Check RTD
Cables and FTS, page 87.
A and B setpoints too low.
Increase A and B setpoints.
Hose is designed to maintain
temperature, not to increase it.
Ambient temperature is too cold. Increase A and B setpoints to
increase ﬂuid temperature and
keep it steady.
Flow too high.
Use smaller mix chamber.
Decrease pressure.
Hose was not fully preheated.
Wait for hose to heat to correct
temperature before spraying.
A and/or B heaters are overheating Check primary heaters for either
material.
a RTD problem or a failed
element attached to RTD, see
Electrical Schematics, page 154.
Faulty FTS connections.
Verify that all FTS connections are
snug and that pins of connectors
are clean. Unplug and re-plug
RTD wires, cleaning off any debris.
Ambient temperature is too high. Cover hoses or move to a location
with a lower ambient temperature.

332637C

Troubleshooting

Problem

Erratic hose temperature.

Hose does not heat.

332637C

Cause

Faulty FTS connections.

Solution

Verify that all FTS connections are
snug and that pins of connectors
are clean. Unplug and re-plug
FTS wires along length of hose,
cleaning off any debris.
FTS not installed correctly.
FTS should be installed close to
end of hose in same environment
as gun. Verify FTS installation,
see Repair Fluid Temperature
Sensor (FTS), page 88.
FTS failed.
Check FTS, see Repair Fluid
Temperature Sensor (FTS), page
88.
FTS not installed correctly.
FTS should be installed close to
end of hose in same environment
as gun. Verify FTS installation,
see Repair Fluid Temperature
Sensor (FTS), page 88.
Loose hose electrical connections. Check connections. Repair as
necessary.
Circuit breakers tripped.
Reset breakers (CB20 and CB02),
see Repair Circuit Breaker Module,
page 77.
Hose zone not turned on.
Turn on hose heat zone.
A and B temperature setpoints too Check. Increase if necessary.
low.
Failed TCM.
Remove TCM and install a new
TCM. New module comes with
current software. Update other
modules if necessary. See
software installation instruction
manual.

Troubleshooting

Problem

Cause

Solution

Hoses near Reactor are warm, but Shorted connection or failed hose With power off, check the hose
hoses downstream are cold.
heating element.
resistance with and without the
whip hose attached. With the whip
hose attached, the reading should
be less than 3 ohm. Without the
whip hose attached, the reading
should be OL (open loop). See
Check Hose Heat Connectors,
page 87.
Low hose heat.
A and B temperature setpoints too Increase A and B setpoints. Hose
low.
designed to maintain temperature,
not increase temperature.
Hose temperature setpoint too Check. Increase if necessary to
low.
maintain heat.
Flow too high.
Use smaller mix chamber.
Decrease pressure.
Low current; FTS not installed. Install FTS, see operation manual.
Hose heat zone not turned on long Allow hose to heat up, or preheat
enough to reach setpoint.
ﬂuid.
Loose hose electrical connections. Check connections. Repair as
necessary.
Ambient temperature is to low
Relocate hoses to a warmer area
or increase A and B setpoints.

332637C

Troubleshooting

Booster Heater

Before performing any troubleshooting procedures:
1. Relieve Pressure. See Pressure Relief Procedure, page 60.
2. Turn main power switch OFF.
3. Allow equipment to cool.
Problems

Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also,
determine that all circuit breakers, switches, and controls are properly set and wiring is correct before
assuming there is a problem.
Problem

Booster heater(s) does not heat.

Cause

Heat turned off.
Temperature control alarm.
Signal failure from RTD.
Failed heater element.

Control of booster heat is
Loose RTD connections.
abnormal; high temperature
overshoots (T4DA, T4DB) occurs
intermittently.
RTD not contacting heater
element.
Failed heater element.
Signal failure from RTD.

332637C

Solution

Turn on heat zones.
Check ADM for error codes.
Signal failure from RTD.
See
Replace Heater Element, page 84.
Examine RTD cables connected
to TCM. Conﬁrm RTDs are not
plugged into opposite heat zone.
Reconnect RTD connectors.
Loosen ferrule nut, push in RTD
so tip contacts heater element.
Holding RTD tip against heater
element, tighten ferrule nut 1/4
turn past tight.
See
Replace Heater Element, page 84.
See (T4DA, T4DB), Error Codes.

Troubleshooting

Load Center Diagnostics

Reference Replace Load Center Relays and Fuses, page 79, and Electrical Schematics, page 154. The LEDs
on the load center board are helpful diagnostic tools when troubleshooting problems with the engine. Before
referencing the Engine Troubleshooting, page 53, complete the following steps:
1. Identify which LEDs are on and off.

Load Center Component Identiﬁcation
Figure 1
F3 Radiator Fan Fuse
F4 Load Center Power Fuse
K1 Fuel Relay
K2 Starter Relay
K3 Glow Plug Relay
K4 Radiator Fan Relay
MV Manual Valve Switch
LED

D1
D2
D3
D4
D10
D12
D14
D23

Related Component

Fuel Shutoff Solenoid
Starter
Glow Plugs
Radiator Fan
A Coolant Valve
B Coolant Valve
Bypass Coolant Valve
Manual Valve Switch

Manual Valve Switch ON (engine off)
Figure 2

Color

Green
Red
Green
Green
Red
Blue
Green
Red

ON-State Description

Fuel shutoff solenoid on the engine is open.
Starter is cranking.
Glow plugs are heating.
Radiator fan is on.
A-side (red) coolant valve is open.
B-side (blue) coolant valve is open.
Bypass coolant valve is open.
Manual valve switch is in the ON position.

332637C

Troubleshooting

2. Determine if the LEDs are expected to be in
the state observed. Determine if an unlit LED
should be on by referring to the LED Expected
Operation table.

Table 1 lists a likely order of potential failures in the
load center output-side components.
Table 1 – LEDs Light As Expected

Fuel
(D1)

Note

The starter, fuel shutoff solenoid, glow
plugs, and radiator fan operations are
sequenced during startup by the Engine
Control Module.

1
2

LED Expected Operation

LED

ON State

On when fuel is being fed to the engine –
from shortly before the starter cranks until
the engine is turned off.
On when starter is cranking – from shortly
after the Fuel LED lights (beginning
approximately 8 seconds after the green
start button on the Engine Control Module
is pressed) and until shortly after the engine
turns over.
On when glow plugs are warming the
engine - from when the green start button is
pressed on the Engine Control Module until
shortly after the engine starts and comes
up to speed.
On when radiator fan is running – from
shortly before the starter cranks until
shortly after the main power switch is
turned on, then intermittently thereafter as
required by engine temperature. (If the
main power switch is left off, the fan will run
continuously.)

3. If the LEDs light as expected, focus
troubleshooting attention to components listed in
Table 1. If the LEDs do not light as expected, ﬁrst
focus troubleshooting attention to components
listed in Table 2.
4. For potential causes and solutions related
to the components in Tables 1 and 2, see
Engine Troubleshooting, page 53.

332637C

Starter
(D2)

Glow Plugs
(D3)

Radiator
Fan
(D4)

Engine Harness (E) and its connections
Engine
Starter
Glow Plugs
Fuel
Solenoid
Solenoid
Shutoff
Relay
Relay
Solenoid
(CR6)
(CR7)
(FD)
Engine
Starter
Motor (ES)

Table 2 indicates a likely order of potential failures in
the load center input-side power, cable, or control
components.
Table 2 – LEDs Do Not Light As Expected

Fuel
(D1)
1
2
3

4
5
6
7
8
9
10

Starter
(D2)

Glow
Plugs
(D3)

Radiator
Fan
(D4)

Battery
Battery cables and its connections
No D2 LED
Disconnect
switch ON
Load
Center
Load Center Fuse F4
Fuse F3
("PWR - ATO 20A")
("FAN ATO 30A")
Fusible Link Harness (C) and its connections
Engine Harness (E) and its connections
Engine Control Module Harness (F) and
its connections
Load
Load
Load
Load
Center
Center
Center
Center Fan
Fuel Relay
Starter
Glow
Relay (K4)
(K1)
Relay (K2) Relay (K3)
Load Center Board
Engine Control Module

Troubleshooting

LED

Description

Off
On
Flashing

4. Engine starting; glow plugs continue to warm
engine.

LED Sequence for Engine Startup and Operation

1. After pressing green start button on Engine
Control Module, glow plugs start warming engine.
5. Engine is running; with main power switch off,
the radiator fan runs continuously.

2. Fuel and radiator fan turn on shortly before
engine starting; glow plugs continue to warm
engine.
6. Engine is running; electronics take control of and
cycle the fan and valves beginning shortly after
main power switch is turned on.

3. Engine starting; fuel, fan, and glow plugs
continue to operate.

332637C

Troubleshooting

Engine

Contact Perkins for diesel engine service or warranty. See Supplied Manuals, page 14.

Problem

Cause

Engine Control Module does not Discharged or failed battery.
power up from sleep mode.
Loose or incorrect wiring
connections.

Blown Load Center board fuse.
Blown fusible link.

Failed Engine Control Module.
Failed Load Center board.

332637C

Solution

Verify battery voltage is 11 - 13
volts DC.
Charge or replace battery as required. See
Replace Battery, page 97.
Verify wiring connections
(including grounds) related
to Engine Control Module.
Check Engine Harness (E),
Engine Control Module Harness
(F), Fusible Link Harness
(C), and battery cables. See
Electrical Schematics, page 154.
Verify voltage is 11 - 13 volts DC
from starter to ground.
Determine cause of blown fuse
F4 "PWR - ATO 20A". Repair
issue then replace fuse. See
Replace Load Center Relays and
Fuses, page 79.
Verify continuity through
fusible link harness from
starter to 12V charge alternator. If required, replace
Fusible Link Harness (C). See
Electrical Schematics, page 154.
See Repair Fusible Link Harness,
page 98.
Replace module. See Replace
Engine Control Module, page 101.
Replace board. See
Replace Load Center, page 80.

Troubleshooting

Problem

Cause

Reference Load Center Diagnostics, page 50.
Engine does not turn over.
Main power switch on electrical
enclosure is in the ON position.
Discharged or failed battery.
Loose or corroded battery cable
connector.
Loose or incorrect wiring
connections.

Blown Load Center board fuse.
Failed starter relay.
Failed starter solenoid relay.
Blown fusible link.

Failed load center board (242).
Failed engine control module
(428).
Failed engine starter (ES).

Solution

Turn switch to OFF position.
Verify battery voltage is 11 - 13
volts DC.
Charge or replace battery as required. See
Replace Battery, page 97.
Verify cable connectors. See
Replace Battery, page 97.
Verify wiring connections
(including grounds) related to
starter. Check Engine Harness
(E), Engine Control Module
Harness (F), Fusible Link Harness
(C), Disconnect Check Harness
(H), and battery cables. See
Electrical Schematics, page 154.
Verify voltage is 11 - 13 volts DC
from starter to ground.
Determine cause of blown fuse
F4 "PWR - ATO 20A". Repair
issue then replace fuse. See
Replace Load Center Relays and
Fuses, page 79.
Replace relay K2 located
on Load Center board. See
Replace Load Center Relays and
Fuses, page 79.
Replace solenoid relay CR6
located on side of engine. See
Replace Engine Solenoid Relays,
page 80.
Verify continuity through
fusible link harness from
starter to solenoid relay
CR6. If required, replace
Fusible Link Harness (C). See
Electrical Schematics, page 154.
Replace board. See
Replace Load Center, page 80.
Replace module. See Replace
Engine Control Module, page 101.
Contact local Perkins distributor
for service.

332637C

Troubleshooting

Problem

Cause

Reference Load Center Diagnostics, page 50.
Engine turns over, but does not Low fuel level.
start.
Lost prime.

Solution

Reﬁll fuel tank.
Ensure fuel tank is at least half full,
prime with bulb until fuel is ﬂowing
through return line to tank.
Loose or incorrect wiring
Verify wiring connections
connections.
(including to grounds) related
to engine fuel shutoff solenoid.
Check Engine Harness (E), Engine
Control Module Harness (F), and
Fusible Link Harness (C). See
Electrical Schematics, page 154.
Blocked air intake.
Replace air ﬁlter.
Blocked exhaust system.
Check that exhaust system is
open (rain cap is free to move, no
exhaust obstructions or plugging).
Remove blockage.
Blocked fuel ﬁlter.
Inspect/replace fuel ﬁlter.
Replace relay K1 located
Failed fuel relay.
on Load Center board. See
Replace Load Center Relays and
Fuses, page 79.
Solenoid valve rod stuck in
Remove valve rod and clean with
extended position.
WD-40.
Failed engine fuel shutoff solenoid. Verify engine fuel shutoff solenoid
(FD) related wiring according to
schematics (see Cause "Loose
or incorrect wiring connections",
above).
Contact local Perkins distributor
for service.
Failed glow plug relay.
Replace relay K3 located on
Load Center board. See Replace
Engine Solenoid Relays, page 80.
Failed glow plug solenoid relay. Replace solenoid relay CR7
located on side of engine. See
Replace Engine Solenoid Relays,
page 80.
Failed glow plug assembly.
Verify glow plug related wiring
according to schematics (see
Cause "Loose or incorrect wiring
connections", above).
Contact local Perkins distributor
for service.

332637C

Troubleshooting

Problem

Cause

Reference Load Center Diagnostics, page 50.
Engine shuts down, Engine
Loose or incorrect wiring
Control Module shows no errors. connections.

Solution

Verify wiring connections
(including grounds) related to
engine fuel shutoff solenoid.
Check Engine Harness
(E), and Engine Control
Module Harness (F). See
Electrical Schematics, page 154.
Replace relay K1 located
Failed fuel relay.
on Load Center board. See
Replace Load Center Relays and
Fuses, page 79.
Failed engine fuel shutoff solenoid. Verify engine fuel shutoff solenoid
(FD) related wiring according to
schematics (see Cause "Loose
or incorrect wiring connections",
above).
Contact local Perkins distributor
for service.

332637C

Troubleshooting

Problem

Cause

Reference Load Center Diagnostics, page 50.
Engine shuts down, Engine
Low engine coolant level.
Control Module shows High
Coolant Temperature Shutdown
icon.
Engine water temperature switch
failed or shorted out.

Solution

Inspect coolant system for leaks.
Repair as necessary and reﬁll
system.
Check for shorts to
switch wiring. See
Electrical Schematics, page 154.
Loose or incorrect wiring
Verify wiring connections
connections.
(including grounds) related to
radiator fan. Check Engine
Harness (E), and Engine Control
Module Harness (F). See
Electrical Schematics, page 154.
Blown radiator fan fuse.
Determine cause of blown fuse
F3 "FAN - ATO 30A". Repair
issue then replace fuse. See
Replace Load Center Relays and
Fuses, page 79.
Replace relay K4 located
Failed radiator fan relay.
on Load Center board. See
Replace Load Center Relays and
Fuses, page 79.
Obstructed radiator fan.
Remove obstructions.
Failed radiator fan.
Replace fan. See
Replace Radiator Fan, page 83.
Failed engine coolant temperature Replace engine coolant
sensor.
temperature sensor located
behind radiator connected
to MCM port 3. See
Replace Engine RTD, page 105.
Plugged radiator or coolant
Clean or replace radiator. See
system.
Remove Radiator, page 100.
Contact local Perkins distributor
for service.

332637C

Troubleshooting

Problem

Engine shuts down. Engine
Control Module shows Low Oil
Pressure Shutdown icon.

Cause

Low oil level.
Loose or incorrect wiring
connections.
Failed oil pressure switch.

Engine shuts down. Engine
Control Module shows Under
Frequency Shutdown icon
or Generator Low Voltage
Shutdown icon .

Low fuel level.
Lost prime.
Blocked air intake.
Blocked exhaust system.
Blocked fuel ﬁlter.
Generator overloaded.
Loose or incorrect wiring
connections.
Blown voltage sense fuses.

Solution

Check oil level and reﬁll.
Verify wiring connections
(including grounds) related to
oil pressure switch. Check
Engine Harness (E), and Engine
Control Module Harness (F). See
Electrical Schematics, page 154.
Replace oil pressure switch
Contact local Perkins distributor
for service.
Reﬁll fuel tank.
Ensure fuel tank is at least half full,
prime with bulb until fuel is ﬂowing
through return line to tank.
Replace air ﬁlter.
Check that exhaust system is
open (rain cap is free to move, no
exhaust obstructions or plugging).
Remove blockage.
Replace fuel ﬁlter.
Conﬁrm auxiliary electrical loads
wired into the electrical enclosure
by the customer are within the
system's available auxiliary power
limits.
Verify wiring connections related
to Engine Control Module, Check
AC Sense Harness (M). See
Electrical Schematics, page 154.
Replace fuses F6 and F7 located
in the junction box above the
120/240 V alternator. Use repair
kit 24M723.

332637C

Troubleshooting

Graco InSite
Problem

No module status LEDs are
illuminated.

Cause

No power to cellular module.

Solution

Turn Reactor power ON.
Ensure cable is installed between
cellular module and power supply
and MCM.
Has not identiﬁed GPS location Still identifying location.
Wait a few minutes for the unit to
(green module status LED
identify the location.
ﬂashing).
Unable to identify location. In a Move system to a location with a
location where GPS lock cannot clear view of the sky.
occur. Buildings and warehouses Use extension cable 16X521 and
move cellular module to a location
often prevent GPS locks.
with a clear view of the sky.
Has not established cellular
Still establishing cellular
Wait a few minutes for the unit to
connection (orange module status connection.
establish the connection.
Unable to establish cellular
Move system to a location with
LED ﬂashing).
connection.
cellular service to establish cellular
connection.
Use extension cable 16X521 and
move cellular module to a location
with a clear view of the sky.
Cannot view data for my unit(s) on Graco InSite unit has not been Activate unit. See Registering
website.
activated.
and Activating the Graco InSite
section.
Reactor temperature data not
Reactor temperature
See System troubleshooting
displayed on website.
measurement is not working.
section.
Hose zone temperature data not The RTD is not correctly installed See RTD repair section.
displayed on website.
on the hose or is broken.
Reactor pressure data not
Reactor pressure measurement is See System troubleshooting
displayed on website.
not working.
section.

332637C

Pressure Relief Procedure

Route ﬂuid to waste containers or supply tanks.
Pressure Relief Procedure 4. Turn
PRESSURE RELIEF/SPRAY valves (SA,
Follow the Pressure Relief Procedure
whenever you see this symbol.

This equipment stays pressurized until pressure
is manually relieved. To help prevent serious
injury from pressurized ﬂuid, such as skin injection,
splashing ﬂuid and moving parts, follow the
Pressure Relief Procedure when you stop spraying
and before cleaning, checking, or servicing
equipment.

SB) to PRESSURE RELIEF/CIRCULATION
. Ensure gauges drop to 0.

5. Engage gun piston safety lock.

The Fusion AP gun is shown.

1. Relieve pressure in gun and perform gun
shutdown procedure. See gun manual.
2. Close gun ﬂuid inlet valves A and B.

Fusion

Probler

6. Disconnect gun air line and remove gun ﬂuid
manifold.

Probler

3. Shut off feed pumps and agitator, if used.

332637C

Shutdown

Shutdown system to avoid electric shock. All
electrical wiring must be done by a qualiﬁed
electrician and comply with all local codes and
regulations. To help prevent serious injury from
pressurized ﬂuid, such as skin injection, splashing
ﬂuid and moving parts, follow the Pressure Relief
Procedure when you stop spraying and before
cleaning, checking, or servicing equipment.
Immediate Shutdown

NOTICE

To avoid system damage, follow daily shutdown
procedure. Use only for immediate shutdown.
For immediate shutdown, press:

2. Turn off all heat zones.

3. Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to PRESSURE RELIEF/CIRCULATION .

4. Relieve pressure. See
Pressure Relief Procedure, page 60.
5. Press to park the Component A Pump. The
park operation is complete when green dot goes
out. Verify the park operation is complete before
moving to next step.
Daily Shutdown

NOTICE

Proper system setup, startup, and shutdown
procedures are critical to electrical equipment
reliability. The following procedures ensure steady
voltage. Failure to follow these procedures will
cause voltage ﬂuctuations that can damage
electrical equipment and void the warranty.
1. Press

332637C

6. Press

to deactivate the system.

to stop the pumps.

Shutdown

7. Turn off the air compressor, air dryer, and
breathing air.

8. Close the main air shutoff valve.

9. Turn main power switch OFF. Allow engine
cooling dwell time prior to shutting down the
engine.

To prevent electric shock do not remove any
shrouds or open the electrical enclosure door.
240 V is still present in the system until the
engine has stopped.
NOTICE

Allow engine cooling dwell time, per
manufacturer recommendations, prior to
shutdown. Dwell time will help engine
properly cool down after running at operating
temperature for any period of time. Stopping
the engine immediately after running it at
full load for an extended period of time can
cause the engine to overheat due to the lack of
coolant ﬂow. See engine manual.
10. Press to stop the engine.

11. Close all ﬂuid supply valves.

332637C

Shutdown

12. Engage gun piston safety lock then close ﬂuid
inlet valves A and B.

Fusion

332637C

Probler

Flushing

To avoid ﬁre and explosion:
• Flush equipment only in a well-ventilated area.
• Do not turn on heaters until ﬂuid lines are clear
of solvent.
• Flush out old ﬂuid with new ﬂuid, or ﬂush out old
ﬂuid with a compatible solvent before introducing
new ﬂuid.
• Use the lowest possible pressure when ﬂushing.
• All wetted parts are compatible with common
solvents. Use only moisture-free solvents.

To ﬂush feed hoses, pumps, and heaters
separately from heated hoses, set PRESSURE
RELIEF/SPRAY valves (SA, SB) to PRESSURE
RELIEF/CIRCULATION
lines (N).

. Flush through bleed

To ﬂush entire system, circulate through gun ﬂuid
manifold (with manifold removed from gun).
To prevent moisture from reacting with
isocyanate, always leave the system ﬁlled
with a moisture-free plasticizer or oil. Do not
use water. Never leave the system dry. See
Important Isocyanate Information, page 9.

332637C

Repair

Repairing this equipment requires access to parts
that may cause electric shock or other serious
injury if work is not performed properly. Be sure to
shut off all power to equipment before repairing.
Before Beginning Repair
NOTICE

1. Close the ﬂuid inlet valve at the pump inlet and
shut off the appropriate feed pump. This prevents
material from being pumped while cleaning the
screen.
2. Place a container under the strainer base to catch
drain off when removing the strainer plug (C).
3. Remove the screen (A) from the strainer
manifold. Thoroughly ﬂush the screen with
compatible solvent and shake it dry. Inspect the
screen. No more than 25% of the mesh should
be restricted. If more than 25% of the mesh is
blocked, replace the screen. Inspect the gasket
(B) and replace as required.
4. Ensure the pipe plug (D) is screwed into the
strainer plug (C). Install the strainer plug with the
screen (A) and gasket (B) in place and tighten.
Do not overtighten. Let the gasket make the seal.
5. Open the ﬂuid inlet valve, ensure that there are
no leaks, and wipe the equipment clean. Proceed
with operation.

Flush Inlet Strainer Screen
A

The inlet strainers ﬁlter out particles that can plug the
pump inlet check valves. Inspect the screens daily as
part of the startup routine, and clean as required.
Isocyanate can crystallize from moisture
contamination or from freezing. If the chemicals used
are clean and proper storage, transfer, and operating
procedures are followed, there should be minimal
contamination of the A-side screen.

Figure 3

C
D

Note

Clean the A-side screen only during
daily startup. This minimizes moisture
contamination by immediately ﬂushing
out any isocyanate residue at the start of
dispensing operations.

332637C

Repair

Drain Coolant
LED Component

To avoid burns, do not perform maintenance on
the coolant system until the coolant system has
reached ambient temperature.
Drain coolant from the engine and proportioner
coolant loops once a year or if the coolant lines need
to be disconnected, in order to install a wall between
the generator and proportioner.
1. Perform Shutdown, page 61.
2. Open the cabinet door on the front of the
proportioner.
3. Turn on manual valve switch (MV), located on
the load center (LC), to manually open the A
and B heat exchanger control valves and bypass
control valve.
Note

The 12V battery must be connected to
operate valves. The load center (LC)
LEDs will stay on when the manual valve
switch (MV) is in the on position.

MV
LC

LED Color

Manual valve switch (MV) Red
Red
A Side Control Valve
Blue
B Side Control Valve
Bypass Valve
Green
4. To drain proportioner coolant loop:
a. Remove the proportioner coolant loop ﬁll
bottle (HF) cap.

b. Place the other end of the drain tube in a
waste container. Open the drain valve. Drain
coolant until coolant is no longer visible in
the sight glass.

Proportioner Coolant Loop Drain Valve
Figure 5
c. To reﬁll coolant loop, see
Reﬁll Proportioner Coolant Loop, page 68.

Figure 4

332637C

Repair

5. To drain proportioner coolant loop from ﬁlter
housing. Only available on Series B systems.
a. Remove the proportioner coolant loop ﬁll
bottle cap (HF).

b. Remove engine guards as shown. Let the
guards rest on the engine to access the drain
valve.

5&
+)

7
'

Filter Housing Drain Valve (D)
Figure 6
b. Place the other end of the ﬁlter housing drain
tube (T) in a waste container. Open the drain
valve (D).
c. To reﬁll coolant loop, see
Reﬁll Proportioner Coolant Loop, page 68.
6. To drain engine coolant loop:
a. Remove the engine coolant loop (RC) cap.

332637C

Engine Coolant Loop Drain Valve
Figure 7
c. Place a waste container under the drain
valve. Open the drain valve and drain
coolant.
d. To reﬁll coolant loop, see
Reﬁll Engine Coolant Loop, page 69.
e. Replace engine shrouds. Torque screws to
25 ft-lbs (33.8 N∙m).

Repair

Reﬁll Proportioner Coolant Loop

Purge air from proportioner coolant loop when it is
ﬁlled with new coolant or when air enters the coolant
system.
Note

It takes about one full warm-up and
cool-down cycle to purge air from coolant.

NOTICE

To prevent leaks, do not interchange the two
caps between the radiator and coolant bottle.
The caps have different pressure ratings that
affect the overﬂow.
2. Remove the caps from the metal proportioner
coolant loop ﬁll bottle (HF) and expansion
bottle (HB). Fill the proportioner coolant loop ﬁll
bottle (HF) to the top and add more coolant to
expansion bottle (HB) until the coolant is at the
cold ﬁll line. See Coolant Speciﬁcations, page 70.

To avoid burns, do not perform maintenance on
the coolant system until the coolant system has
reached ambient temperature.
Only use coolant solutions that are compatible with
the system. See Coolant Speciﬁcations, page 70.
NOTICE

Do not reﬁll with drained coolant. Use only fresh,
new coolant to avoid contaminants.
NOTICE

Do not use any “stop leak” additives to prevent
plugged ﬁlters and small oriﬁces.
1. Before reﬁlling coolant loop, perform steps 1–3
from Drain Coolant, page 66. Drain coolant loop
if necessary.

Coolant System Bottles
Figure 8

332637C

Repair

3. Replace cap and tighten past the safety latch
position.
4. Press start button twice on the engine
control module.
5. Turn main power switch on.

Only use coolant solutions that are compatible with
the system. See Coolant Speciﬁcations, page 70.
NOTICE

Do not reﬁll with drained coolant. Use only fresh,
new coolant to avoid contaminants.
NOTICE

6. Inspect coolant ﬂow in sight glass (SG) for
bubbles and to verify that the coolant is ﬂowing.
7. Inspect coolant loops for leaking ﬁttings or valves.
8. The coolant has reached operating temperature
when the radiator fan turns on. When the fan
turns on, turn the main power switch off.
9. Press to stop the generator.
10. After the coolant system temperature lowers to
ambient temperature, reﬁll or add coolant to the
expansion bottle (HB) cold level indicator line.
11. Turn off manual valve switch (MV) to close the A
and B heat exchanger control valves (VA, VB)
and bypass control valve (VC).
Note

Do not use any “stop leak” additives to prevent
plugged ﬁlters and small oriﬁces.
1. Perform Shutdown, page 61.
NOTICE

To prevent leaks, do not interchange the two
caps between the radiator and coolant bottle.
The caps have different pressure ratings that
affect the overﬂow.
2. Remove the engine radiator coolant cap (RC)
and ﬁll until the coolant reaches the bottom
of the neck. See Fig 8. Replace cap. See
Coolant Speciﬁcations, page 70.
3. Remove the cap from the engine coolant loop
bottle (EB) and ﬁll until the coolant is at the hot
level. Replace cap.
4. Press start button twice on the engine
control module.
5. Turn main power switch on.

When the manual valve switch (MV) is
in the off position, the load center (LC)
LEDs only turn on when the system
opens the valves.
12. If necessary, reﬁll or add coolant to the expansion 6. Inspect coolant loops for leaking ﬁttings or valves.
7. The coolant has reached operating temperature
bottle (HB) cold level indicator line. See Fig 8.
when the radiator fan turns on. When the fan
turns on, turn the main power switch off.
Reﬁll Engine Coolant Loop

Reﬁll the engine coolant loop when the coolant is
below the cold level line at ambient temperature.
To avoid burns, do not perform maintenance on
the coolant system until the coolant system has
reached ambient temperature.
332637C

8. Press to stop the generator.
9. Add more coolant to expansion bottle (EB)
after the coolant system temperature lowers to
ambient temperature. Repeat until coolant level
stays at cold level when at ambient temperature.
It may take a few cycles to remove all air out of
coolant system.
69

Repair

Coolant Speciﬁcations
NOTICE

Do not reﬁll with straight water or tap water.
Changing the 50% mix ratio use of tap water will
allow ﬁttings to rust.
Only reﬁll the coolant loops with a solution of 50%
distilled or soft water and 50% green ethylene glycol
antifreeze with a corrosion inhibitor. Do not use
common tap water; it contains chlorides and minerals
which form scale on the coolant system walls. Do not
use any stop leak products. The additives in these
products will clog the heat exchanger and ﬂuid valves,
decreasing system performance. Use only antifreeze
that meets speciﬁcation ASTM D3306–89, BS658, or
AS 2108. A pre-diluted mix is recommended, such
as PEAK Ready Use 50/50 Pre-Diluted.

To change pump lubricant:
1. Follow Pressure Relief Procedure, page 60.
2. Lift the lubricant reservoir (R) out of the bracket
and remove the container from the cap. Holding
the cap over a suitable container, remove the
check valve and allow the lubricant to drain.
Reattach the check valve to the inlet hose.
3. Drain the reservoir and ﬂush it with clean
lubricant.
4. When the reservoir is ﬂushed clean, ﬁll with fresh
lubricant.
5. Thread the reservoir onto the cap assembly and
place it in the bracket.
6. The lubrication system is ready for operation. No
priming is required.

Change Pump Lubricant

Check the condition of the ISO pump lubricant daily.
Change the lubricant if it becomes a gel, its color
darkens, or it becomes diluted with isocyanate.
Gel formation is due to moisture absorption by the
pump lubricant. The interval between changes
depends on the environment in which the equipment
is operating. The pump lubrication system minimizes
exposure to moisture, but some contamination is still
possible.
Lubricant discoloration is due to continual seepage of
small amounts of isocyanate past the pump packings
during operation. If the packings are operating
properly, lubricant replacement due to discoloration
should not be necessary more often than every 3 or
4 weeks.

Pump Lubrication System
Figure 9

332637C

Repair

Remove Pump

9. Allow engine dwell time.
NOTICE

Pump rod and connecting rod move during
operation. Moving parts can cause serious injury
such as pinching or amputation. Keep hands and
ﬁngers away from connecting rod during operation.
Note

1.
2.
3.
4.
5.
6.
7.

See manual 309577 for pump repair
instructions.
Press to stop the pumps.
Turn off heat zones.
Flush pump.
Press to park the Component A Pump.
Press to deactivate the system.
Turn off the air compressor, air dryer, and
breathing air.
Close the main air shutoff valve.

Allow engine dwell time, per manufacturer
recommendations, prior to shutdown. Dwell
time will help engine cool down after running at
operating temperature for any period of time.
10. Press on the engine control module.
11. Open air compressor bleed valve to relieve
pressure and remove water from tank.
12. Shut off both feed pumps. Close all ﬂuid supply
valves.

13. Route ﬂuid to waste containers or supply tanks.
Turn PRESSURE RELIEF/SPRAY valves (SA,
SB) to PRESSURE RELIEF/CIRCULATION
. Ensure gauges drop to 0.

8. Turn main power switch off.

To prevent electric shock do not remove any
shrouds or open the electrical enclosure door.
240 V is still present in the system until the
engine has stopped.

332637C

Repair
Note

Use drop cloth or rags to protect Reactor
and surrounding areas from spills.
Note

Steps 14–16 apply to pump A. To
disconnect pump B, go to steps 17 and
18.
14. Disconnect ﬁttings at ﬂuid inlet (C) and outlet (D).
Also disconnect steel outlet tube from heater
inlet.
15. Disconnect tubes (T). Remove both tube ﬁttings
(U) from wet-cup.
16. Loosen locknut (G) by hitting ﬁrmly with a
non-sparking hammer. Unscrew pump far
enough to expose rod retaining pin. Push
retaining wire clip up. Push pin out. Continue
unscrewing pump.

Pump B
Figure 11
Flat side faces up.

Lubricate threads with ISO oil or grease.
Pump top threads must be nearly ﬂush with
bearing face (N).

2
3

Install Pump
Note

1.
2.
Pump A
Figure 10
1
2
3

Flat side faces up.
Lubricate threads with ISO oil or grease.
Pump top threads must be nearly ﬂush with
bearing face (N).
Note

Steps 17 and 18 apply to pump B.
17. Disconnect ﬂuid inlet (C) and outlet (D). Also
disconnect steel outlet tube from heater inlet.
18. Push retaining wire clip (E) up. Push pin (F)
out. Loosen locknut (G) by hitting ﬁrmly with a
non-sparking hammer. Unscrew pump.
72

3.
4.
5.

Steps 1–5 apply to pump B. To reconnect
pump A, proceed to step 6.
Ensure locknut (G) is screwed on pump with ﬂat
side up. Screw pump into bearing housing (M)
until pin holes align. Push pin (F) in. Pull retaining
wire clip (E) down. See Fig. 11, page 54 for view
and assembly notes.
Continue screwing pump into housing until ﬂuid
outlet (D) is aligned with steel tube and top
threads are +/- 1/16 in. (2 mm) of bearing face
(N).
Tighten locknut (G) by hitting ﬁrmly with a
non-sparking hammer.
Reconnect ﬂuid inlet (C) and outlet (D).
Go to step 13.
Note

Steps 6–12 apply to pump A only.
6. Ensure star-shaped locknut (G) is screwed on
pump with ﬂat side up. Carefully twist and extend
displacement rod 2 in. (51 mm) above wet-cup.
7. Start threading pump into bearing housing (M).
When pin holes align, insert pin. Pull retaining
wire clip down.
8. Continue threading pump into bearing housing
(M) until top threads are +/- 1/16 in. (2 mm) of
332637C

Repair

bearing face (N). Ensure that barbed ﬁttings at
wet-cup ﬂush ports are accessible.
9. Connect component A outlet tube loosely at
pump and at heater. Line up tube, then tighten
ﬁttings securely.
10. Tighten star-shaped locknut (G) by hitting ﬁrmly
with a non-sparking hammer.
11. Apply thin ﬁlm of TSL to barbed ﬁttings. Using
two hands, support tubes (T) while pushing
straight onto barbed ﬁttings. Secure each tube
with a wire tie between two barbs.
Note

Do not let tubes kink or buckle.
12. Reconnect ﬂuid inlet (C).
13. Purge air and prime the system. See Reactor
operation manual.

3.
4.
5.
6.

Flush pump.
Press to park the Component A Pump.
Press to deactivate the system.
Turn off the air compressor, air dryer, and
breathing air.
7. Close the main air shutoff valve.
8. Turn main power switch off.

Repair Drive Housing

Removal

1. Press to stop the pumps.
2. Turn off heat zones.

332637C

To prevent electric shock do not remove any
shrouds or open the electrical enclosure door.
240 V is still present in the system until the
engine has stopped.

Repair

9. Allow engine dwell time.
NOTICE

Allow engine dwell time, per manufacturer
recommendations, prior to shutdown. Dwell
time will help engine cool down after running at
operating temperature for any period of time.
10. Press on the engine control module.
11. Open air compressor bleed valve to relieve
pressure and remove water from tank.
12. Perform Pressure Relief Procedure, page 60.
13. Remove screws (294) and motor shield (293),
see Fig. 12.
Note

Examine bearing housing (303) and
connecting rod (305). If these parts need
replacing, ﬁrst remove the pump (315),
see Remove Pump, page 71.
14. Remove cover (74) and screws (75).
15. Remove cycle switch (321) from A side drive
housing. Remove screws (322) and cycle switch
(321).
16. Disconnect pump inlet and outlet lines. Remove
screws (313), washers (314), and bearing
housing (303).

Figure 12

NOTICE

Do not drop gear cluster (304) when removing
drive housing (302). Gear cluster may stay
engaged in motor front end bell (R) or drive
housing.
17. Remove screws (312) and pull drive housing
(302) off motor (301).
Note

The A side drive housing includes
cycle counter switch (321). Switch wire
connects to port #12 on the MCM.

Figure 13
Installation

1. Apply grease liberally to washers (307, 308,
318), all gears, and inside drive housing (302).
2. Install one bronze washer (308) in drive housing,
then install steel washers (307, 318) as shown.
3. Install second bronze washer (308) on gear
cluster (304) and insert gear cluster in drive
housing.
Note

Drive housing crankshaft must be in line
with crankshaft at other end of motor.
See Fig. 13, page 56.
74

332637C

Repair

4. Push drive housing (302) onto motor (301).
Install screws (312).
Note

If bearing housing (303), connecting rod
(305), or pump (315, 306) were removed,
reassemble rod in housing and install
pump, see Install Pump, page 72 .

5. Install cycle counter switch (3210) and screws
(322).
6. Install bearing housing (303), screws (313), and
washers (314). Pumps must be in phase (both at
same position in stroke).
7. Install cover (74) and screws (75).
8. Install motor shield (293) and screws (294).

Figure 14

332637C

Repair

Repair Electric Motor

Removal
NOTICE

Be careful not to drop or damage the motor. The
motor is heavy and may require two people to lift.
1. Remove drive housing and pump assemblies.
See Repair Drive Housing, page 73.
2. Disconnect electric motor (301) power cable from
port #15 on the MCM.
3. Remove screws (294) and motor shield (293).
Rest motor shroud assembly behind the motor
without straining the fan power cable.

Installation

1. Place motor on unit. Thread motor
cables into conduit as before. See
Electrical Schematics, page 154.
2. Fasten motor (301) with screws (268) until
screws are fully threaded in mounting bracket.
Do not tighten screws until drive housing and
pumps are connected to the motor.
Note

3.
4.
4. Disconnect over temperature cable from port
#2 on MCM. Cut tie wraps around harness to
remove cable.
5. Remove four screws (268) holding motor (301) to
bracket. Lift motor off unit.
5.
6.

If necessary, loosen screws (268) to
align the motor (301) with side brackets.
Install drive housing and pump assemblies, see
Installation, page 74.
Route motor (301) power cable from motor
through top port into Reactor cart, through back
port out of the Reactor, through cord grip (518),
and into the electrical enclosure. Connect to port
#15 on MCM. Use tie wraps to secure power
cable to other cables on pallet.
Install drive housing covers and motor cover.
Return to service.

332637C

Repair

b. Follow Shutdown instructions. See
Shutdown, page 61.
c. Refer to circuit breaker identiﬁcation table
and electrical diagrams in Reactor repair
manual.
d. Loosen four screws connecting wires and bus
bar to circuit breaker that will be replaced.
Disconnect wires.
e. Pull locking tab out 1/4 in. (6mm) and pull
circuit breaker away from the din rail. Install
new circuit breaker. Insert wires and tighten
down all screws.

Repair Circuit Breaker Module

1. See Before Beginning Repair, page 65.
2. Using an ohmmeter, check for continuity across
circuit breaker (left to right). If no continuity, trip
breaker, reset, and retest. If still no continuity,
replace breaker as follows:
a. Refer to Electrical Schematics, page 154,
and tables on next page.

Circuit Breakers
Figure 15
Ref.

Size

CB01

CB02
CB03

15 A
15 A

332637C

CB01
CB02
CB03
CB04
CB05
CB06
CB07
CB08

15 A

20 A

40 A

20 A

TB12 TB11

30 A

15 A

PS1

Ref.

Component

Power Supply, Fan,
Coolant Pump
Boost Heat A
Boost Heat B

CB04
CB05
CB06*
CB07*
CB08*

Size

30 A
20 A
40 A
20 A
15 A

Component

Hose Heat
Motor Control
Air Compressor/Open
Open
Air Dryer/Open

Repair

Circuit Breakers Inside Cabinet
Figure 16
Ref.

CB20

Size

50 A

Component

Heated Hose

Circuit Breakers Inside Alternator Assembly
Figure 17
Ref.

CB10

Size

90 A

Component

120/240V Alternator

332637C

Repair

Replace Load Center Relays and
Fuses

1. Disconnect the negative lug from the negative
post of the battery. See Replace Battery, page 97.
2. Remove the bad relay or fuse from the load
center (242) and install a new relay or fuse. See
Fig. 18.
3. Connect battery cable. See
Replace Battery, page 97.
Relay and Fuse Identiﬁcation Table

See Load Center Wiring Diagram, page 163.
Repair
Kit

Ref

Load Center Relay and Fuse Identiﬁcation
Figure 18

Component

Fuel Relay
Starter Relay
Glow Plug Relay
Fan Relay
Fuse for load center
relay K4 and radiator
fan.
Fuse for load center
relays K1, K2, K3
24L959
and their related
F4 PWR-ATO - 20A components; Engine
Control Module
power; and coolant
valve control.
K1
K2
24L958
K3
K4
F3 FAN-ATO - 30A

332637C

Repair

Replace Load Center

Replace Engine Solenoid Relays

1. Perform Shutdown, page 61.
2. Disconnect the negative lug from the negative
Before handling board, put on a static conductive
post of the battery. See Replace Battery, page 97.
wrist strap to protect against static discharge which
3. Remove two bolts (570) and solenoid relay (569).
can damage board. Follow instructions provided
The starter solenoid relay (CR6) is above the
with wrist strap.
glow plug solenoid relay (CR7).
1. Perform Shutdown, page 61.
4. Disconnect cables from the old relay
and connect to the new relay. See
2. Disconnect the negative lug from the negative
Load Center Wiring Diagram, page 163.
post of the battery. See Replace Battery, page 97
3. Disconnect all connectors. See
Load Center Wiring Diagram, page 163.
4. Remove four nuts (248), and load center (240).
5. Install new load center (240) and
reconnect all connectors. See
Load Center Wiring Diagram, page 163.
6. Connect battery cable. See
Replace Battery, page 97.
NOTICE

Starter (top) and Glow Plug (bottom) Solenoid Relays
Figure 19

332637C

Repair

Replace Fluid Inlet Sensor

1. Perform Shutdown, page 61.
2. Perform Pressure Relief Procedure, page 60.
3. Disconnect inlet sensor cable from the
ﬂuid inlet assembly. Inspect cable for
damage and replace if necessary. See
Electrical Schematics, page 154.

Figure 20 Fluid Inlet Sensor
4. To replace sensor cable:
a. Open wire bundle and remove sensor cable.
b. Cut any wire ties and disconnect from MCM.
See Electrical Schematics, page 154.

5. Replace sensor (866).
Replace Pressure Transducers

1. Perform Shutdown, page 61.
2. Perform Pressure Relief Procedure, page 60.
3. Disconnect transducer cables (455) from #6 and
#7 connectors on the MCM. Reverse A and B
connections and check if error code P6AX or
P6BX follows the transducer. See Error Codes.
4. If transducer fails test, thread cable through top
of cabinet. Note path as cable must be replaced
in same way.
5. Install o-ring (466) on new transducer (455).
6. Install transducer in manifold. Mark end of cable
with tape (red=transducer A, blue=transducer B).
7. Route cable into cabinet and thread into bundle
as before.
8. Connect A side pressure transducer cable
to MCM port #6. Connect B side pressure
transducer cable to MCM port #7.

NOTICE

To prevent damage to cable, route and
secure cable in wire bundle and wire ties
as before.

332637C

Repair

Replace Fans

Shutdown system to avoid electric shock. To avoid
burns, do not perform maintenance on the fan until
the system has reached ambient temperature.
Replace Motor Fan

1.
2.
3.
4.

Perform Shutdown, page 61.
Remove eight screws (75) and covers (74).
Remove four screws (294) and cover (293).
Refer to Electrical Schematics, page 154. Check
connections of all wires going to terminal blocks
TB21 and TB22. Verify that all screws are tight.
Using an voltmeter, check for 24 volts DC across
TB21(+) and TB22(-). Replace cable (22), if zero
volts are read. If volts are correct and fan doesn’t
spin, replace fan.
5. Remove nuts (292) and fan (212).
6. Install new fan (212) in reverse order.

Replace Proportioner Module Fan

1. Perform Shutdown, page 61.
2. Remove cabinet panel (70).
3. Refer to Electrical Schematics, page 154. Check
connections of all wires going to terminal blocks
TB21 and TB22. Verify that all screws are tight.
Using an voltmeter, check for 24 volts DC across
TB21(+) and TB22(-). Replace cable (22), if zero
volts are read. If volts are correct and fan doesn’t
spin, replace fan.
4. Remove fan (212).
5. Install new fan (212) in reverser order of
disassembly.

Figure 22
Figure 21

332637C

Repair

Replace Radiator Fan

Replace Electrical Enclosure Fan

1. Perform Shutdown, page 61.
1. Perform Shutdown, page 61.
2. Remove four screws (605) and disconnect power 2. Open electrical enclosure door (502). Loosen
cable (PC).
four nuts (558) and remove fan (561).
3. Install new fan (605) to radiator bracket (601)
3. Refer to Electrical Schematics, page 154. Check
with screws (605).
connections of all wires going to terminal blocks
TB13, TB14, and power supply PS1. Verify that
all screws are tight. Using an voltmeter, check
for 24 volts DC across TB13(+) and TB14(-).
Replace power supply PS1 (515), if zero volts
are read. If volts are correct and fan doesn’t spin,
replace fan.
4. Install new fan (561) in reverse order of
disassembly so that the fan blows out of the
electrical enclosure.

Figure 23

Figure 24

332637C

Repair

Repair Booster Heater

Replace Heater Element

1.
2.
3.
4.
5.
6.

Press to stop the pumps.
Turn off heat zones.
Flush pump.
Press to park the Component A Pump.
Press to deactivate the system.
Turn off the air compressor, air dryer, and
breathing air.
7. Close the main air shutoff valve.
8. Turn main power switch off.

To prevent electric shock do not remove any
shrouds or open the electrical enclosure door.
240 V is still present in the system until the
engine has stopped.
9. Allow engine dwell time.
NOTICE

Allow engine dwell time, per manufacturer
recommendations, prior to shutdown. Dwell
time will help engine cool down after running at
operating temperature for any period of time.

10. Press on the engine control module.
11. Open air compressor bleed valve to relieve
pressure and remove water from tank.
12. Perform Pressure Relief Procedure, page 60.
13. Wait for heater to cool.
14. Remove heater shroud (266).
15. Disconnect heater element wires from heater
wire connector. Test with ohmmeter.
Total Heater
Wattage

4,000

Element

Ohms

2000

23–26.5

Note

The A-side heater element is located
in the booster heater end nearest the
B-side pump and the B-side heater
element is located near the A-side pump.
16. To remove heater element, ﬁrst remove
RTD (360) to avoid damage. See step 7,
Replace RTD, page 85.
17. Remove heater element (357) from housing
(351). Be careful not to spill any ﬂuid left in
housing. See Fig. 25.
18. Inspect element. It should be relatively smooth
and shiny. If there is a crusted, burnt, ash-like
material adhered to element or sheath shows
pitting marks, replace element.
19. Install new heater element (357), holding mixer
(359) so it does not block RTD port (P).
20. Reinstall RTD (360), Replace RTD, page 85.
21. Reconnect heater element leadwires to heater
wire connector.
22. Replace heater shroud (266).
Line Voltage

The heater outputs its rated wattage at 240 VAC.
Low line voltage will reduce power available and the
heater will not perform at full capacity.

332637C

Repair

Repair Overtemperature Switch

1.
2.
3.
4.

Perform Shutdown, page 61.
Wait for booster heater to cool.
Remove heater shroud.
Verify blue wire and brown/black wires
from cable (54) ”HTR-OT” are connected
to overtemperature switch (358). See
Electrical Schematics, page 154.
5. Disconnect overtemperature switch (358) from
cable (54). Test across quick connect terminals
with an ohmmeter.
a. If the resistance
approximately 0 ohms,
the overtemperature switch needs to be
replaced. Go to step 6.
b. If the resistance approximately 0 ohms,
test the cable to ensure it is not cut or open.
Reconnect the overtemperature switch
and cable. Disconnect the cable from the
overtemperature port on the TCM. Test
from pin 1 to pin 3 and pin 1 o pin 4 on
cable (54) “HTR-OT”. Resistance should be
approximately 0 ohms.
is not

Note

The cable may have failed if one or both
of the readings is above approximately 0
ohms. If the readings is approximately
0 ohms, then there may have been a
bad connector/connection causing the
problem.
6. If switch fails test, remove screws. Discard failed
switch. Apply a thin layer of thermal compound
110009, install new switch in same location on
housing (351), and secure with screws (361).
Reconnect cables.

332637C

Replace RTD

1. Perform Shutdown, page 61.
2. Wait for heater to cool.
3. Remove heater shroud (266) and heater guards
(299, 300).
4. B Side RTD:
a. Follow “HT- RTD-B" RTD cable (360) and
open split loom about 18 in. (457.2 mm) away
from the heater attachment. Disconnect “HTRTD-B TCM" and “HT-RTD-B” connectors.
See Electrical Schematics, page 154.
b. Visually inspect “HT-RTD-B” connector and
replace extension cable (58) if necessary.
Continue to next step if the extension cable
connector is not damaged.
c. Visually inspect “TCM-A HT-RTD-B”
connection to TCM. Continue to next step to
replace RTD (360).
5. A side RTD:
a. Follow “HT- RTD-A" RTD cable (360) and
open split loom about 18 in. (457.2 mm) away
from the heater attachment. Disconnect “HTRTD-A TCM" and “HT-RTD-A” connectors.
See Electrical Schematics, page 154.
b. Visually inspect “HT-RTD-A” connector and
replace extension cable (58) if necessary.
Continue to next step if the extension cable
connector is not damaged.
c. Visually inspect “TCM-A HT-RTD-A”
connection to TCM. Continue to next step to
replace RTD (360).
85

Repair

6. Loosen ferrule nut (N). Remove RTD (360) from
heater housing (351), then remove RTD housing
(H). Do not remove the adapter (355) unless
necessary. If adapter must be removed, ensure
that mixer (359) is out of the way when replacing
the adapter.
7. Replace RTD (360).
a. Apply PTFE tape and thread sealant to male
pipe threads and tighten RTD housing (H)
into adapter (355).
b. Push in RTD (360) so tip contacts heater
element (357).
c. Holding RTD (360) against heater element,
tighten ferrule nut (N) 3/4 turn past
ﬁnger-tight.

8. Route wires (S) as before through split loom
and reconnect RTD cable (360) to the B side
extension cable (71) or the A side extension
cable (58).
9. Replace heater shroud and heater guards.
10. Follow startup instructions in the operation
manual. Turn on A and B heat simultaneously to
test. Temperatures should rise at same rate. If
one is low, loosen ferrule nut (N) and tighten RTD
housing (H) to ensure RTD tip contacts element
(357) when ferrule nut (N) is retightened.

Figure 25

332637C

Repair

Repair Heated Hose

Refer to the heated hose manual 309572 for hose
replacement parts.
Check Hose Heat Connectors

1. Perform Shutdown, page 61.

5. If the FTS is not reading properly at the end of
the hose, connect FTS directly to RTD cable (C)
at the manifold.
6. If the FTS reads properly at the manifold but
not at the end of the hose, check cable (C)
connections. Verify they are tight.

Note

Whip hose must be connected.
2. Disconnect hose connector (V) at Reactor, see
Fig. 26.
3. Using an ohmmeter, check between the
connectors (V). There should be continuity.
4. If hose fails test, retest at each length of hose,
including whip hose, until failure is isolated.
Check RTD Cables and FTS

1. Perform Shutdown, page 61.
2. Disconnect RTD cable (C) at Reactor.
3. Test with an ohmmeter between pins of cable
connector C.
Note

Do not touch outer ring with test probe.

Pins

3 to 1

Result

approximately 1090
ohms
3 to 4
approximately 1090
ohms
1 to 4
0.2 - 0.4 ohms
2 to any
inﬁnity (open)
4. Retest at each length of hose, including whip
hose, until failure is located.

332637C

Heated Hose
Figure 26
Note

To assist in taking readings, order RTD
Test Kit 24N365. Kit includes two cables:
one cable with a compatible female M8
connector and another cable with a male
M8 connector. Both cables have stripped
wire at the other end for easy test probe
access.
Pins / Wire Color

Result

3 to 1 / brown to blue approximately 1090
ohms
3 to 4 / blue to black approximately 1090
ohms
1 to 4 / brown to black 0.2 - 0.4 ohms
2 to any / N/A
inﬁnity (open)

Repair

Repair Fluid Temperature Sensor
(FTS)

Installation

The Fluid Temperature Sensor (FTS) is supplied with
the system. Install FTS between main hose and
whip hose. See Heated Hose manual 309572 for
instructions.

Figure 27
Test/Removal

1. Perform Shutdown, page 61.
2. Remove tape and protective covering from FTS.
Disconnect hose cable (F).
3. If FTS is not reading properly at the end of the
hose, see Check RTD Cables and FTS, page 87.
4. If FTS fails, replace FTS.

a. Disconnect air hoses (C,L) and electrical
connectors (D).
b. Disconnect FTS from whip hose (W) and
ﬂuid hoses (A, B).
c. Remove ground wire (K) from ground screw
on underside of FTS.
d. Remove FTS probe (H) from component A
(ISO) side of hose.

332637C

Repair

Transformer Primary Check

1. See Shutdown, page 61.
2. Locate the two smaller (10 AWG) wires, labeled
1 and 2, coming out of transformer. Trace these
wires back to terminal blocks TB23 and TB24.
Use an ohmmeter to test for continuity between
two wires; there should be continuity.
Transformer Secondary Check

1. See Shutdown, page 61.
2. Locate the two larger (6 AWG) wires, labeled 3
and 4, coming out of transformer. Trace these
wires back to circuit breaker CB20 (906). Open
the circuit breaker to turn the color indicator on
the circuit breaker GREEN. Use an ohmmeter to
test for continuity between two transformer wires
in circuit breaker terminals 1 and 3; there should
be continuity.
3. Close the circuit breaker CB20 (906).

Figure 28
4. Conﬁrm main power switch is off before starting
generator.

332637C

5. Start the generator.
Press start button twice on the engine
control module. The controller will automatically
sequence glow plug warming and crank
operations. Allow engine to reach full operating
speed.
Note

Engine will not start if main power switch
is in the on position.
6. Turn main power switch on.
7. Press

to turn on hose heat zone.

This equipment is used with heated ﬂuid which
can cause equipment surfaces to become very
hot. To avoid severe burns:
• Do not touch hot ﬂuid or equipment.
• Allow equipment to cool completely before
touching it.
• Wear gloves if ﬂuid temperature exceeds
110°F (43°C).
• Do not turn on hose heat without ﬂuid in
hoses.

Thermal expansion can cause
overpressurization, resulting in equipment
rupture and serious injury, including ﬂuid
injection. Do not pressurize system when
preheating hose.

Repair

8. To verify voltage on the secondary leads of the Replace Transformer
transformer, measure between the terminals 2
and 4 on CB20. This will verify the circuit breaker 1. Perform Shutdown, page 61.
is working properly.
2. Open Reactor cabinet.
3. Remove bolts holding transformer (226) to
cabinet ﬂoor.
310 ft
90 Vac*
4. Disconnect the transformer wires. See
210 ft
62 Vac*
Reactor Cabinet Wiring Diagram, page 162.
* For 240 Vac line voltage.
5. Remove transformer (226) from cabinet.
9. See the Diagnostic Run Screen on the ADM. The 6. Install new transformer (226) in reverse order.
Diagnostic Run Screen displays the incoming
(240 Vac) to the TCM “Hose Voltage” and the
hose current. The diagnostic screen will show
if the circuit breaker has been tripped for the
incoming power to the TCM.
Model

Secondary Voltage

226

332637C

Repair

Replace Heat Exchangers

1. If a wall is installed between the generator and
the proportioner, remove the proportioner from
the pallet. See Remove Proportioner, page 102.
2. Perform Flushing, page 64.
3. Perform Shutdown, page 61.
4. Perform Drain Coolant, page 66.
5.
a. Remove fuel tank. See
Remove Fuel Tank, page 96.
b. Disconnect both RTD connectors (284). See
Replace Heat Exchanger RTD, page 93.
c. Disconnect A and B material lines from
swivel ﬁttings (297).
For proportioner heat exchangers:

332637C

Proportioner Heat Exchangers
Figure 29
d. Disconnect hose clamps (37, 239) from heat
exchanger assembly (241).
e. Remove four nuts (249) and the heat
exchanger assembly (241). Pull heat
exchanger assembly out of coolant hoses.
f. Install a new heat exchanger assembly
(241) by following the removal steps in
reverse order. Orient control valves as
shown. Continue to next step to remove heat
exchangers (802) or (803).

Repair

g. Disconnect two swivel ﬁttings (805) and
swivel ﬁttings on heat exchanger outlet (806)
from the heat exchangers (802, 803).

For the engine heat exchanger:

a. Disconnect swivel ﬁttings (617) and (618)
from heat exchanger (614).
b. Remove nuts (612), washers (613), and heat
exchanger (614). Set expansion bottle and
bracket aside.
c. Install new heat exchanger (614) in reverse
order by following the removal steps in
reverse order.

Proportioner Heat Exchangers
Figure 30
h. Remove four nuts (810) and washers (811)
for replacing heat exchangers (802) or (803).
Engine Heat Exchanger
Figure 31

332637C

Repair

Replace Heat Exchanger RTD

1. Perform Shutdown, page 61.
2. Remove Reactor cabinet cover.
3. Disconnect RTD from CAN cable.
NOTICE

ISO and RES will release when either RTD is
removed from the heat exchangers. To prevent
damage to load center and other electronics,
protect all electronics from chemicals released
from the heat exchanger RTD ports.
4. Remove compression ﬁtting (272) from the back
of the heat exchanger with RTD (273) attached.

The RTD probe cannot be removed from the
compression nut.
NOTICE

To ensure accurate temperature readings, only
use RTD Kit 24L972.
5. Tighten compression ﬁtting (272) on RTD sheath
(273).
6. Apply thread sealant to compression ﬁtting pipe
threads (272 and install in heat exchanger.
7. Connect new RTD to extension cable (71).

Figure 32

332637C

Repair

Replace Control Valve

Replace Power Supply

Follow these instructions to replace a control valve
solenoid coil or remove the component A control
valve, component B control valve, or the bypass
control valve.
1. Perform Shutdown, page 61.
1. Perform Shutdown, page 61.
2. Drain coolant from the proportioner coolant loop. 2. Disconnect power supply (655) from circuit
See Drain Coolant, page 66.
breaker CB01 and terminal blocks TB13 through
TB15. See Electrical Schematics, page 154.
3. To repair the control valve, remove the four
nuts (VN) and washers (VW). Remove the front 3. Insert a ﬂat head screw driver in the mounting
of the control valve, diaphragm, and gaskets.
tab on the bottom of the power supply (655) to
Purchase Valve Repair Kit 125774. For complete
remove from the din rail.
installation instructions see the Control Valve
Kits manual 3A1932.
4. To remove the solenoid coil (SC), loosen
connector screw and disconnect the coolant
valve harness (D). Remove the nut (SN)
and washer (SW) from coil. Purchase Valve
Coil Replacement Kit 125787. For complete
installation instructions see the Control Valve
Kits manual 3A1932.

Figure 33

4. Install new power supply (655) in reverse order.

332637C

Repair

Replace Circulation Pump

To prevent burns, do not perform maintenance on
the coolant system until the coolant system has
reached ambient temperature.
1. Perform Shutdown, page 61.
2. Perform Drain Coolant, page 66.
3. If a wall is installed and the circulation pump can
not be accessed, remove the proportioner. See
Remove Proportioner, page 102.
4. Disconnect pump ﬁttings (234) from swivel ﬁtting
(275).
5. Remove pump cover (C).

6. Press in tabs to disconnect power wires (W).
7. Remove four outside nuts (254). Hold on to the
pump ﬂanges (234) and remove the circulation
pump (233). Remove four inside nuts (254) to
remove ﬂanges from the pump.
8. Place o-rings, supplied with the new circulation
pump (233), between the pump and the ﬂange
ﬁttings (234). Insert screws (255) through the
pump and ﬂange ﬁttings (234) and tighten four
nuts on screws (255).
9. Place circulation pump (233) on brackets (223)
so that coolant will ﬂow towards the sight glass.
Install four nuts (254) on screws (255).
10. Connect power wires to pump and replace cover.
See Reactor Cabinet Wiring Diagram, page 162.
11. Connect ﬂange ﬁttings (234) to swivel on the
elbow ﬂange ﬁtting (234) and ﬁtting (275).

Figure 34

332637C

Repair

Repair Filter Housing Filter

Remove Fuel Tank

1. Drain the proportioner coolant loop. See
Drain Coolant, page 66.
2. Remove cap (C) and ﬁlter (643) from ﬁlter
housing (630).
3. Pull out ﬁlter (643). Brush out ﬁlter and replace
if necessary.
4. Insert ﬁlter (643) into cap (C) and tighten cap into
ﬁlter housing (630).

1. Perform Shutdown, page 61 .
2. Disconnect fuel lines (38, 39). Keep elevated or
plug to prevent siphoning.
3. Remove screws (24) and clamps (30).
4. Slide the fuel tank off the B side of the pallet.
5. Inspect for any damage.
6. Slide fuel tank on to pallet and secure to pallet
with screws (24) and clamps (30). Reconnect
fuel lines (38, 39).
7. Squeeze prime bulb (P) to prime engine. Press
the prime bulb repeatedly until fuel begins to
return to the fuel tank.

Figure 35

332637C

Repair

Replace Battery

Improper battery installation or maintenance
may result in electric shock, chemical burns,
or explosion. Battery maintenance must only
be performed or supervised by personnel
knowledgeable of batteries and the required
precautions. Keep unauthorized personnel away
from batteries.
See Technical Speciﬁcations, page 175 for battery
requirements and recommended battery size.
1. Remove plastic caps (PC) from battery terminals
and disconnect battery cables from battery.
2. Disconnect strap and remove battery.
3. Place new battery on bracket and secure with
strap.
4. Reconnect battery cables and cover battery
terminals with plastic caps (PC). Ensure red

332637C

cable is connected to the positive (+) battery
post. Connect black cable to the negative (-)
battery post.

Figure 36
NOTICE

Always connect the red battery cable to battery
positive (+) terminal and the black battery cable
to the battery negative (-) terminal. Failure to
properly connect the battery cable to the battery
will damage the fusible link harness. Do not bypass
the fusible link when damaged. The fusible link
prevents damage to other system components.

Repair

Repair Fusible Link Harness

4. Remove fusible link harness (90) from engine.
5. Carefully cut open heat shrink encasing the fuse
holder along lines shown.

Follow this procedure to replace fuses
inside the fusible link harness (90). See
Electrical Schematics, page 154, for fusible link
harness connections and wire identiﬁcation.
1. Perform Shutdown, page 61.
2. Disconnect battery from system.
3. Determine which fuse (F8, F9) needs to be
replaced.
6. Pull away heat shrink. Squeeze the fuse holder
cover and disconnect from base latches. If
a. Cut cable tie (81) and remove red insulator
latches break off, replace entire fuse holder with
cap (111) over the positive stud on the
fuse holder (118) shipped loose with the system.
engine starter. Remove the outside nut (106)
and red battery cable (47) . Disconnect
fusible link harness (90) ring terminal from
the engine starter.

b. Using a multimeter, measure continuity
7. Remove two M5 nuts from fuse holder base.
through the harness ring terminals. See
Table 1.
8. Replace blown 60 amp fuse in the fuse holder
base with new fuse (117). New fuse (117) is
c. If one of the two wire paths measures “open”,
shipped loose with the system.
then the fuse (F8, F9) in that path is blown
and needs to be replaced.
Table 1 Fusible Link Harness Connections

Fuse (117)

Wire No.

C010 and C030

Engine starter positive
power lug

C010 and C030

Engine starter positive
power lug

Ring Terminal Location

Wire No.

C020
C040
C050

Ring Terminal Location

12 V charge alternator B+
terminal
Starter solenoid relay
(CR6)
Glow plug solenoid relay
(CR7)

332637C

Repair

9. Replace M5 nuts over fuse and ring terminals.
Torque to 44 in.-lbs (5 N●m).
10. Connect fuse holder cover to fuse holder base.
Wrap entire fuse holder and heat shrink 3–4
times with tape (44).
NOTICE

Ensure tape entirely covers heat shrink.
Failure to seal the cut heat shrink with tape
may allow ﬂuid to contact fusible link and
damage the fusible link.
11. Connect fusible link harness (90) and battery
cable to engine starter with nuts (106). Secure
to solenoid relay bracket with cable ties (81),
shipped loose with system.
12. Snap the cap insulator (111) over the red battery
cable (47). Position the red cap insulator so that
the stud is not exposed.

332637C

13. Insert cable tie (81) through cap insulator (111)
and tighten to the red battery cable (47). Ensure
that the stud is not exposed.
14. Reconnect black battery cable to the negative (-)
battery terminal and the red battery cable to the
positive (+) battery terminal.
NOTICE

Always connect the red battery cable to battery
positive (+) terminal and the black battery cable
to the battery negative (-) terminal. Failure
to properly connect the battery cable to the
battery will damage the fusible link harness.
Do not bypass the fusible link when damaged.
The fusible link prevents damage to other
system components.

Repair

Remove Radiator
NOTICE

Do not damage ﬁns on radiator. Damaged radiator
ﬁns will result in poor radiator performance or
cause a coolant leak.
1. Drain the engine coolant loop. Follow
Drain Coolant, page 66.
2. Remove radiator air exhaust duct, if used.
3. Remove screws (17) and back panel (8).
Figure 38
7. Inspect radiator for any obstructions. Replace or
have serviced, if necessary.
8. Install new radiator assembly in reverse order.
9. Follow Reﬁll Engine Coolant Loop, page 69.
Replace Advanced Display Module
(ADM)

1. Loosen screw in bracket (402). Lift up on bracket
(402) and remove ADM (27).
2. Disconnect CAN cable (57).
3. Inspect ADM for damage. Replace if necessary.

Figure 37
4. Remove eight screws (605), top bracket (604),
and bottom bracket (606).
5. Loosen hose clamps (622) and coolant hose
from radiator (603) inlet and outlet.
6. Carefully swing the bottom of the radiator (603)
away from the engine and lift out of cover (601).
Figure 39
100

332637C

Repair

Replace Engine Control Module

1. Perform Shutdown, page 61.
2. Remove two top screws (17) and loosen the two
side screws to lower the back panel (28).
3. Disconnect harness (M) and harness
(F) connectors from the back of the
engine control module (428). See
Engine Control Module Wiring Diagram, page 164
4. Loosen engine control module mounting screws
and remove the engine control module (428).
5. Install new engine control module (428) in air
control panel. Secure clips in place and tighten
mounting screws.
6. Connect all wire harnesses and close the back
panel with two screws (17).
Replace Temperature Control Module
(TCM)

1.
2.
3.
4.
5.

Perform Shutdown, page 61.
Open electrical enclosure door (501).
Disconnect all connectors from the TCM (503).
Remove four nuts (530) andTCM (503).
Install new TCM module (503). Reassemble
parts in reverse order.

Figure 40
Replace Motor Control Module (MCM)

1. Perform Shutdown, page 61.
2. Disconnect connectors from MCM (504).
Disconnect two power cables. See
Electrical Schematics, page 154.
3. Remove nuts (530) and MCM (504).
4. Set rotary switch. 0= E–30i and 1= E-XP2i.
5. Connect cables to MCM. See
Electrical Schematics, page 154.
332637C

101

Repair

Remove Proportioner

Only remove the proportioner from the pallet to repair
the heat exchangers or coolant valves between the
proportioner and generator.
The back of the proportioner could slide off of the
pallet and support brackets during removal and
installation. Never remove the proportioner from
the system pallet alone. Always use two or more
people and supports.
1. Perform Shutdown, page 61.
2. Drain the proportioner coolant loop. See
Drain Coolant, page 66.
3. Place an empty pallet in front of the proportioner
(23) and center the pallet cross beam with the
proportioner.

Figure 42
5. Cut the cable tie that secures the wire harnesses
behind the A side of the proportioner (23) to the
pallet (1).
6. Disconnect engine wire harness E connectors
(49) from J1 and J2 from the load center (242).
See Load Center Wiring Diagram, page 163. Cut
engine harness cable ties inside the proportioner
cabinet and pull out the backside of the cabinet.
7. Disconnect the engine coolant temperature cable
(59).
Note

Figure 41
4. Loosen the coolant clamps (37) and disconnect
the proportioner coolant outlet and inlet coolant
lines (36).

102

The cable connections will be almost
under the fuel tank mounting location. If
necessary, remove fuel tank or access
the connector from other side of wall.
8. If a wall is installed between the proportioner
(23) and generator continue to step 9. See
Remove Fuel Tank, page 96, if the fuel tank (29)
is mounted on the pallet (1).

332637C

Repair

9. Loosen the front two mounting screws (24) and
remove the back two mounting screws (24).
The back of the proportioner could slide off
of the pallet and support brackets during
removal and installation. Never remove the
proportioner from the system pallet alone.
Always use two or more people and supports.
10. Use 6 in. x 6 in. x 11 in. pieces of wood (S1, S2,
S3, and S4) to support the proportioner during
the removal and installation process.

Figure 43

332637C

11. Place two supports near both sides of the front of
the proportioner (23) . Have one person carefully
tip the proportioner forward and the other person
center the four supports under both sides of the
proportioner frame.
12. Have one person hold the proportioner in place
and the other remove the two front mounting
screws (24).
NOTICE

Do not strain wire harness between
proportioner and electrical enclosure to prevent
damage to connectors.
13. Carefully slide the proportioner (23) off the pallet
support brackets and on to the wood supports.
Continue to slide the proportioner off the front of
the pallet until there is enough space to service
the backside components.
14. Secure the proportioner frame to the empty pallet
you positioned on the ﬂoor with c-clamps.

Figure 44

103

Repair

18. Route the engine wire harness E connectors (49)
15. The proportioner is ready for servicing.
through the back of the proportioner (23) and
16. To install the proportioner (23) on the pallet (1),
connect wire harness connectors to J1 and J2
ensure the wood proportioner frame supports,
connectors on the load center (242). Reconnect
inside the proportioner pallet (1), are aligned with
engine coolant temperature cable (59).
both sides of the proportioner frame.
Secure all harnesses to pallet and inside cabinet
17. Guide cables behind the proportioner (23) when 19. with
cable ties.
sliding the proportioner back to the mounting
position. Secure the proportioner frame to the
pallet with four mounting screws (924). Torque to
40 ft-lbs (54 N•m).

104

332637C

Repair

Repair Engine

Contact your nearest Perkins distributor for repair
and maintenance.
Replace Engine RTD

1. Perform Shutdown, page 61.
2. Drain the engine coolant loop. See
Drain Coolant, page 66.
3. Disconnect RTD cable (632) from extension
cable (59).
4. Remove compression ﬁtting (619) and RTD (632)
from the ﬁtting. The RTD probe (632) cannot be
removed from the compression nut (619).
5. Apply anaerobic sealant to compression ﬁtting
threads (619) and install in ﬁtting at a 30° angle.
Note

To prevent poor heating performance,
use RTD Kit 24L974.
6. Connect new RTD cable (632) to extension cable Figure 45
(59).
7. Reﬁll the engine coolant loop. See
Reﬁll Engine Coolant Loop, page 69.

Figure 46
12V Charge Alternator

Contact your nearest Perkins distributor for repair
and maintenance.

332637C

105

Notes

106

332637C

Parts

Parts
Systems
272079, E-30i
272080. E-30i with Booster Heat
272081, E-XP2i with Booster Heat

For systems with an air compressor, see 272089, 272090, and 272091, page 115.

332637C

107

Parts

108

332637C

Parts

332637C

109

Parts

2
3

Apply anaerobic sealant to all non-swiveling pipe
threads.
Apply lubrication to all push—on hoses prior to
assembly.

Torque to 25 ft-lbs (33.8 N●m).

Torque to 40 ft-lbs (54 N●m).

Torque to 15–20 in.-lbs (1.7–2 N●m).

110

7
9
10

Torque to 25 in-lbs (2.8 N●m).
Safety and warning labels are from label sheet
(55).
Bundle fuel lines above engine, inside ﬂexible
plastic split conduit, with cable ties (81) to avoid
direct contact.

332637C

Parts

Quantity
Ref

1
2

3
4
5
6
7
8
9
10
11
12
14
16
17
18
19
20
21
22
23

Part

24J658
--16H732
24L953
111192
105324
16U131
16H898
16H894
125677
16X025
16K893
123656
115942
113161
16W131
24T051
24T198
125625
24T241
-----

24
25
26
27
29
30
31
32
33

--125626
16V420
--24U854
24K390
16J889
24J690
125166
107251

332637C

Description

BASE, pallet
GENERATOR, diesel, 22kw; see
22 kW Diesel Generator, page 141
SUPPORT, generator
KIT, isolator (4 pack)
SCREW, cap ﬂange hd; 0.875 in. (22 mm), 3/8–16
SCREW, cap, hex hd; 1.2 in (30 mm), M12 x 1.75
GROMMET, tube
GUARD, engine, right
GUARD, engine, left
ROD, connecting, on/off
DOOR, electrical enclosure
HANDLE, selector, on/off
CABLE, 5pin, male/female (matrix)
NUT, hex, ﬂange head; 1/4–20
SCREW, ﬂanged, hex hd; 0.5 in. (13 mm), 1/4–20
CABLE, m12 5p, fem - male, 3.0m
CABLE, m8 4p (f) to m12 8p (m); 3.0 m
HARNESS, ac, power, reactor cart
TIE, cable, ﬁr tree
CABLE, power, 24v, integ reactor
PROPORTIONER, E–30i, (230v, 1ph), see
Proportioners, page 121
PROPORTIONER, E–30i, (4.0kw, 230v, 1ph),
see Proportioners, page 121
PROPORTIONER, E-xp2i, (4.0kw, 230v, 1ph), see
Proportioners, page 121
SCREW, hex hd, ﬂanged; 3 in. (76 mm), 3/8–16
BRACKET, mounting
ENCLOSURE, electrical, see
Electrical Enclosure, page 139
MODULE, GCA, ADM
TANK, fuel, see Fuel Tank, page 148
BRACKET, support, fuel tank
SUPPORT, battery
TRAY, battery
SCREW, pan hd; 1 in. (25.4 mm), #10–24

272079

1
1
1
1
20
4
1
1
1
1
1
1
1
4
18
2
1
1
5
1
1

272080

272081

1
1
1
1
1
1
4
18
2
1
1
5
1

1
1
1
1
20
4

1
6
1
1
1
1
2
1
1
4

6
1
1
1
1
2
1
1
4

1
6
1
1
1
1
2
1
1
4
111

Parts

Quantity
Ref

Part

34✖ 24M174
35 16K214
36a – – –
36b – – –
37 125370
–––
38
–––
39
40 125163
43✖ 206995
44✖ 106569
45 100639
46 127286
47 16K232
48 16K233
49 16K301
50 125751
51 16Y518
52 125753
53 16K299
54 24T242
24U109
55▲ 16K939
56 16X154
57 121002
58 125358
59 122837
60 123652
61 16W596
62 24T199
65 16K362
66 16K363
67 16H910
69 16W245
70✖ 24K207
71 125357
112

Description

STICKS, level, A and B side, 55 gal. (208 l)
HOLDER, cable, tie
HOSE, coolant, 1 in. ID; 2.66 ft (0.81 m)
HOSE, coolant, 1 in. ID; 2.92 ft (0.89 m)
CLAMP, hose, dia. 11/16-1-1/2 in.
HOSE, fuel, 5/16 in.; 3.33 long
HOSE, fuel, 3/16 in.
CLAMP, hose, 7/32-5/8 in.
FLUID, TSL™, 1 qt.
TAPE, electrical
WASHER, lock
CABLE, cordset, reverse key, .5m
CABLE, battery, 30 in. (762 mm), red
CABLE, battery, 30 in. (762 mm), black
HARNESS, dc, diesel, engine
CABLE, grounding, braided, engine
HARNESS, AC, sense, genset control
CABLE, AC, power, 240v alternator
HARNESS, dc, disconnect check
CABLE, over-temp, single reactor
CABLE, over-temp, switch short
LABEL, safety, system, multi
LABEL, Graco InSite
CABLE, can, female / female 1.5m
CABLE, m8, 4-pin, mf, .5meter, mold
CABLE, m8, 4-pin, mf, 3m, molded
CABLE, can, male / female 3.5m
LATCH, door
CABLE, control module, heater
FOAM, support block
SPACER, fuel tank
GASKET, radiator isolation
DOOR, cabinet
KIT, FTS, RTD, single hose; see heated hose manual
CABLE, m8, 4-pin, mf, 1meter, molded

272079

1
4
1
1
4
1
4
6
2
1
3
2
1
1
1
1
1
1
1
1
1
1
1
2
1
4
2
2
1
1
1
3

272080

272081

1
1
1
1
2
1
4
2
2
2
1
1
1
4

1
4
1
1
4
1
4
6
2
1
3
2
1
1
1
1
1
1
1
1

332637C

Parts

Quantity
Ref

72
73

74
75
76
77✖
78
79
80
81
82✖
83✖
84▲
85
86
87
88
89
90
91
93
94
95
97
98
99
101
102
103
104
105
106
109
113

Part

108290
16W216
16W217
277186
118444
190774
125871
125844
16M317
16M319
16M321
333093
333094
15G280
16K172
125754
125755
125822
16K297
----120448
125835
125839
109124
169970
15V551
105329
114816
100186
15V909
110911
126054
186494
169967

332637C

Description

SCREW, mach, binding hd; 1/4 in., #8–32
LABEL, E-30i, elite
LABEL, E–XP2i, elite
COVER, drive, plastic
SCREW, mach, slot hex wash hd; 1/2 in. x #10–24
BLANK, label, kit
TIE, cable, 7.50 in.
CONDUIT, ﬂexible, non-metalic
GUARD, engine, top
GUARD, alternator, mount
GUARD, alternator, plate
QUICK GUIDE, startup
QUICK GUIDE, shutdown
LABEL, safety, warning, multiple
HARNESS, dc, link, fusible
CABLE, AC, alternator breaker, blk
CABLE, AC, alternator breaker, red
CABLE, AC, alternator, n to gnd, wh
HARNESS, DC, genset controller
LABEL, cable, self-lam, top level
KIT, label
SUPPRESSOR, box snap, ferrite
CLIP, ferrite bead
CLIP, ferrite bead
HOSE, coupled, 48 in
FITTING, airline; 1/4–18 NPT (m)
SHIELD, membrane, ADM (10 pack)
NUT, hex; M8 x 1.25
NUT, hex; M6 x 1
WASHER, lock, internal tooth
SCREW, 1/2 in. (12 mm), M8 x 1.25
NUT, hex; M5 x 0.8
INSULATOR, cap
CLIP, spring
FITTING, line air; 1/4–18 NPT (f)

272079

4
1

2
8
2
40
7
1
1
1
1
1
1
1
1
1
1
1
1
2
1
3
1
1
3
1
2
3
1
1
1
1
2
1

272080

272081

2
8
2
40
10.33
1
1
1
1
1
1
1
1
1
1
1
1
2
1
3
1
1
3
1
2
3
1
1
1
1
2
1

1
2
8
2
40
10.33
1
1
1
1
1
1
1
1
1
1
1
1
2
1
3
1
1
3
1
2
3
1
1
1
1
2
1

4
1

113

Parts

Quantity
Ref

114✖
115✖
116
117
118
119
120
121
122
123
124✖
125✖

Part

16P405
16P406
16W213
16D576
113505
16X121
16X122
16X123
16X124
117777
16Y509
16Y516

Description

FUSE, bolt-down, 60A
HOLDER, fuse, bolt-down
LABEL, Reactor
LABEL, made in USA
NUT, keps, hex hd
GASKET, door
GASKET, door
GASKET, door
GASKET, door
HOLDER, vinyl shop ticket
CORE, ferrite, snap-on; 0.76 ID
CORE, ferrite, snap-on; 0.394 ID

▲ Replacement Warning labels, signs, tags, and

cards are available at no cost.

 See Electrical Schematics, page 154.
 Included in Battery Cable Kit 24L962.

114

272079

1
1
2
1
2
2
2
2
2
1
2
1

272080

1
1
2
1
2
2
2
2
2
1
2
1

272081

1
1
2
1
2
2
2
2
2
1
2
1

 Included in Complete Coolant Hose Kit 24L939.

✖

See Complete Coolant Hose Kit, page 131 .
Not shown.

332637C

Parts

272089, E-30i with Air Compressor
272090. E-30i with Booster Heat and Air Compressor
272091, E-XP2i with Booster Heat and Air Compressor

332637C

115

Parts

1
4

116

Apply anaerobic sealant to all non-swiveling pipe
threads.
Use from safety label (55) or (283).

332637C

Parts

Cable Routing

Do not allow cables from starter box to touch
engine. Secure all cables with cable ties (742)
to frame approximately where shown ever 6–12
in. as needed.
Secure with cable ties (742) to pallet tie downs
where shown.

332637C

117

Parts

Parts included with compressor (702b)
Coupler supplied with compressor (702b) needs
to be pressed on to (motor (702a) as shown in
detail view.

Discard plug supplied on compressor and install
thermal switch (702h).

Discard lift ring to install ﬂange.

Torque to 20 ft.-lbs (27 N•m).

Discard steel washer on (702g) before assembly.

Torque to 34 ft.-lbs (46 N•m).

Torque to 36 ft.-lbs (43 N•m).

118

Use only Hydrovane Fluid Force Red 2000
compressor oil. Fill to top of ﬁll plug opening.
One gallon container, Part No. 17A101, is
available as an accessory.

Discard key supplied with motor and replace with
key (702j).

332637C

Parts

Quantity

701* 272079 Reactor, E-30i
1
272080 Reactor, E-30i with heat
272081 Reactor, E-XP2i with heat
* For parts, see 272079, 272080, and 272081, page 107.
Ref

Part

Description

272089

272090

272091

Air Compressor Parts

All air compressor parts are included in the Air Compressor Accessory Kit. See Accessories, page 13.
Ref.

702

702a
702b
702c
702d
702e
702f
702g
702h
702j
702k
703
704
705
706
707
708
709
710
711
712
713
714
715
332637C

Part

Description

16Y567 COMPRESSOR,
tankless, 5 hp; includes
702a-702j
127364 MOTOR, 5 hp
- - - COMPRESSOR,
tankless
107530 SCREW, cap, sch, hex
16X024 COVER overload switch
260067 FITTING, strain relief,
1/2 npt
117625 NUT, locking
16M826 CORD, grip, 3/4 in.
16Y809 SWITCH, thermal
overload
16C282 KEY, square, 1/4
127581 WASHER, bonded seal
127298 DRYER, air
16W780 FRAME, air compressor
16W685 FRAME, air dryer
16W689 BRACKET, clamp
16W843 ROD, threaded, 3/8-16
16W713 STRAP, frame connector
24T849 ENCLOSURE, switch
box
16W577 ENCLOSURE, rear
16W565 BRACKET, electrical box
24U083 STARTER, motor,
reactor
112538 FITTING, elbow, street,
90
127108 FITTING, barbed 5/16 ID
x 1/8 NPT
C20679 FITTING, elbow; 1/2–14
npt x 7/8 un

Qty.

1
1
2
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
2

Ref.

716
717
718
719
720

Part

721
722
723

101577
125856
121488

724
725
726
730
731
732
733
734
735
736
737
738

113504
16X402
111218
125644
17A346
156971
16X520
C19264
512910
16X808
112395
111194

15E511
218093
113505
112958
119865

Description

FITTING, union, swivel
1/2 x 1/4
HOSE, coupled; 1/2–14
npt, 22 in. (559 mm)
NUT, keps, hex hd; #10
NUT, hex, ﬂanged;
3/8–16
SCREW, mach, hex
serrated; 0.375 in. x
1/4–20
SCREW, cap, hex hd;
0.375 in. x #10–24
SCREW, serrated ﬂange;
0.375 in. x #8-32
SCREW, hex hd,
ﬂanged; 2.75 in. x
3/8–16
NUT, keps, hex hd
TUBE, compressor - air
dryer
CAP, tube, square
FITTING, branch tee, 1/2
npt
HOSE, rubber 5/16 in.; 6
ft (1.8 m)
FITTING, nipple, short;
1/4–18 npt x 1/4–18 npt
VALVE, air, 3-way, din
PLUG, pipe plug 1/4 in.
MUFFLER, polyethylene
1/4 in." npt
BRACKET, motor mount
SCREW, cap, ﬂng hd;
3/4 in. x 3/8–16
SCREW, cap ﬂang hd; 2
in. x 3/8–16

Qty.

1
1
3
12
2

3
3
10
2
1
2
1
1
1
1
1
1
2
4
6
119

Parts

Ref.

739
740
741
742

Part

125163
16Y488
106569
261105

Description

Qty.

CLAMP, hose, 7/32 in. –
5/8 in.
NUT, wire, #14-#6 awg 2
TAPE, electrical
1
TIE, cable, 14 in.
10

Ref.

Part

Description

743▲ 189285 LABEL, hot surface
744 190451 UNION, adapter
745 125871 TIE, cable, 7.5 in.

Qty.

1
1
3

▲ Replacement Warning labels, signs, tags, and

cards are available at no cost.

120

332637C

Parts

Proportioners

332637C

121

Parts

122

332637C

Parts

332637C

123

Parts

124

332637C

Parts

332637C

125

Parts

126

Apply anaerobic polyacrylate pipe sealant to all
non-swiveling pipe threads.
Apply grease to tube ﬁtting threads. Torque to
43 ft-lbs (58 N•m).

Safety and warning labels are from label sheet
(283).

Fan air ﬂow towards motor.

332637C

Parts

Quantity
E–30i
Ref

201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230

332637C

Part

--16W233
24T870
16W235
16W608
24V143
16W611
15H189
15G816
15B456
16W609
24R756
16W610
16J758
16W648
103181
112125
116746
191892
117502
117677
16X531
246995
16W183
16W043
15K742
16H761
186494
255716
261821

Description

FRAME
BRACKET, tube guard
MANIFOLD, ﬂuid
BRACKET, tube mount
FITTING, elbow 8jic swivel x 8jicm
KIT, assembly, pair, inlet
FITTING, bulk hd 1/2 nptm x 8 jicm
BOOT, wire feed through
COVER, plate, wire way
GASKET, manifold
FITTING, elbow 1/2 nptf x 8 jicm
FAN, cooling, 120 mm, 24 vdc
FITTING, elbow 1/2 nptf x 10 jicm
COVER, heat exchanger
GROMMET, rubber, 1.0 ID x 1.5 OD
WASHER, lock ext
PLUG, tube
FITTING, barbed, plated; 1/8–27 npt
x 1/4 in. I.D. hose
FITTING, elbow, street, 90°; 1/8 npt
FITTING, reducer #5 x #8 (JIC)
FITTING, reducer #6 x #10 (JIC)
BRACKET, reservoir, lube
RESERVOIR, bottle, assembly
BRACKET, load center
TUBE, pressure relief
TRANSFORMER, 4090 va, 230/90
BRACKET, mounting, pump
CLIP, spring
KIT, heater wire connector
CONNECTOR, wire, 6 AWG

1
1
1
1
2
1
2
2
2
1
1
2
1
1
1
4
2
2
2
1
1
1
1
1
2
1
2
3
2

E–30i with

E-XP2i with

Booster Heat

1
1
1
1
2
1
2
2
2
1
1
2
1
1
1
4
2
2
2
1
1
1
1
1
2
1
2
3
1
2

127

Parts

Quantity
E–30i
Ref

231
232
233
234
235
236
237
238
239
240★
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258-1
258-2
259-3
259-4
260
261
128

Part

24L915
24J699
24K286
16W191
16W193
125170
125371
24K385
24K381
24L957
16H880
--–––
16W184
16X118
125477
112958
113505
117683
126033
111800
125943
125944
114269
126043
126044
24V152

24V153
–––
–––
–––
–––
16W206
16W207

Description

PUMP, centrifugal, circulation
KIT, ﬁtting, pump
KIT, ﬁtting, drain
BRACKET, strainer, left
BRACKET, strainer, right
HOSE, formed, 1 in. ID, lower
CLAMP, hose, dia. 3/4-1-3/4 in.
PANEL, air control
EXCHANGER, heat, assembly
BOARD, load center
COVER, air panel
HOSE, rubber, 5/16 in.
INDICATOR, ﬂow, sight
COVER, fan
MODULE, cellular, GPS
FITTING, 1 in. beaded barb x 3/4
nptm
NUT, hex, ﬂanged
NUT, keps, hex hd
SCREW, mach, phil pan hd; 1.5 in. x
#6–32
TRIM, edge; 0.33 ft (0.1 m)
SCREW, cap, hex hd; 0.625 in. x
5/16–18
NUT, serrated ﬂange; 7/16–14
SCREW, serrated ﬂange; 2.25 in. x
7/16–14
GROMMET, rubber
PLUG, cap, 1.25 diameter hole
PLUG, cap, .75 diameter hole
PROPORTIONER, module, E-30i, no heat; see
Dual Zone 4.0 Kw Fluid Heater
PROPORTIONER, module, E–XP2i;
see Dual Zone 4.0 Kw Fluid Heater
FITTING, A side, inlet, E-30
FITTING, A side, inlet, E-XP2
FITTING, B side, inlet, E-30
FITTING, B side, inlet, E-XP2
TUBE, A-side, hose outlet
TUBE, B-side, hose outlet

1
1
1
1
1
1
4
1
1
1
1
2
1
1
1
1
12
13
8
1
4
8
4
1
2
2
1

E–30i with

E-XP2i with

Booster Heat

1
1
1
1
1
1
4
1
1
1
1
2
1
1
1
1
12
13
8
1
4
8
4
3

1
1

1
1
1
1
1
332637C

Parts

Quantity
E–30i
Ref

262
263
264
266
267
268
269
270
271
272
273
274
275*
276
277
278
279
280
281
282
283▲
284
287
288
289
290
291
292
293

332637C

Part

16W199
16W202
24V145
16K361
121311
125643
113796
24T059
157785
16K646
–––
–––
125625
24L916
16K312
16K311
156589
125535
–––
115836
125857
16W612
198586
261843
125871
295847
260067
151395
127278
16U579

Description

TUBE, A-side, inlet
TUBE, B-side, inlet
HEATER, assy, 4.0kw, hybrid, 2 zone;
see Dual Zone 4.0 Kw Fluid Heater
COVER, horizontal heater
FITTING, connector, 3/8–18 npt x 1/2
jic
FITTING, elbow, 3/8 npt x #8 jic
SCREW, ﬂanged, hex hd; 3/4 in. x
1/4–20
MODULE, breaker, hose, int reactor
FITTING, swivel; 3/-14 nps x 3/4–14
npt
HARNESS, dc, valve, coolant
FITTING, compression, 1/8 npt, ss
SENSOR, RTD, 1 kohm, 4 pin, 4.25
in.
TIE, cable, ﬁr tree
VALVE, solenoid, 3/4 npt, 12 VDC
HOSE, coupled, 26 in. (660 mm)
HOSE, coupled, 18 in. (457 mm)
FITTING, union, adapter, 90°; 3/4 nptf
x 3/4 npsm, 1.25 in.
FITTING, #12 jic swivel x 3/4 npt(m)
HOSE, coolant, 1 in. ID, bulk; 0.33
ft. (0.1 m)
GUARD, ﬁnger
SCREW, serrated ﬂange, hex hd;
.625 in. #10-24
LABEL, safety
CONDUIT, corrugated
FLUID, oxide inhibitor
TIE, cable, 7.50 in.
FITTING, elbow, 90°, 3/4 npt
FITTING, strain relief, 1/2 npt
WASHER, ﬂat
NUT, keps, hex; #6–32
COVER, motor

2
32
1
1
1
2
2
9
1
2
2
4
2
1
1
2
1
1
1
8
2
1
4
4
1

E–30i with

E-XP2i with

Booster Heat

1
1
1
1

2
40
1
1
1
2
2
9
1
2
2
4
2
1
1
2
1
1
1
8
2
1
4
4
1

1
1
1
1

2
40
1
1
1
2
2
9
1
2
2
4
2
1
1
2
1
1
1
8
2
1
4
4
1

129

Parts

Quantity
E–30i
Ref

294
295
296
297
298
299
300

Part

118444
194337
16X129
16W201
16W204
16W203
16W205
17A064
17A066

Description

SCREW, mach, slot hex wash hd; 1/2
in. x #10–24
WIRE, grounding, door
SCREW, mach, phillips, tooth washer,
.375 in. x #8–32
TUBE, A-side, outlet
TUBE, A-side, outlet
TUBE, B-side, outlet
TUBE, B-side, outlet
GUARD, heater, A-side
GUARD, heater, B-side

▲ Replacement Warning labels, signs, tags, and

cards are available at no cost.
★ Purchase Relay Repair Kit 24L958; includes
four relays. Purchase Fuse Repair Kit 24L959;
includes two fuses..
Order 125774 Valve Repair Kit to replace all
internal valve parts. Order 125787 Coil Repair
Kit to replace coil.
 Included in RTD Repair Kit 24L972.

130

4
1
4
1
1

E–30i with

E-XP2i with

Booster Heat

4
1
4
1

1
1

 Included in Sight Glass Kit 24L921.
 Included in Complete Coolant Hose Kit 24L939.

See Complete Coolant Hose Kit, page 131
 Included in Pump Inlet Assembly Kit. See
Pump Inlet Assembly Kits, page 131.
See Electrical Schematics, page 154.
 Not shown.

332637C

Parts

Pump Inlet Assembly Kits
Description

E-30i A Side
E-30i B Side
E-XP2i A Side
E-XP2i B Side

Kit

24L926
24L927
24L928
24L929

Includes:

Qty:

258–1
259–3
258–2
259–4
1

277
277
277
277
1

279
279
279
279
1

Complete Coolant Hose Kit, 24L939
Ref

Description

Systems

36a
36b
37
40

HOSE, coolant, 1 in. ID, 2.66 ft (0.81 m)
HOSE, coolant, 1 in. ID, 2.92 ft (0.89 m)
CLAMP, hose, dia. 11/16-1-1/2 in.
CLAMP, hose, 7/32-5/8 in.

Proportioners, page 121

237 CLAMP, hose, dia. 3/4-1-3/4 in.
242 HOSE, rubber, 5/16 in., 1 ft (0.3 m)
280 HOSE, coolant, 1 in. ID, 0.33 ft (0.1 m)
22 kW Diesel Generator

562 CLAMP, hose, dia. 3/4–1–3/4 in.
Radiator

620
621
622
623
627
628
629
640
641
642

HOSE, formed, 1–1/4 upper radiator
HOSE, coolant, 1 in. ID; 6 in. (152.4 mm)
CLAMP, hose, dia. 3/4–1–3/4 in.
CLAMP, hose, dia. 11/16–1–1/2 in.
HOSE, formed, 1–1/4 lower radiator
HOSE, 1 in. ID; 0.271 ft (0.08 m)
HOSE, 5/16 in. ID; 1.5 ft (0.5 m)
HOSE, formed, 1–1/4 upper engine
CLAMP, hose 7/32 in. - 5/8 in.
HOSE, formed, 1–1/4 lower engine

332637C

Qty.

1
1
2
6
4
2
1
1
1
1
4
2
1
1
1
1
4
1

131

Parts

Proportioner Module
24V152, Module for E-30i
24V153, Module for EXP2i

Torque to 190–120 in-lbs (21–24 N•m).

Lubricate threads with ISO oil or grease. Assemble pump cylinders ﬂush to one full thread under-ﬂush of
housing surface.

Apply grease to all gear teeth proportionally, motor pinion and drive housing.

Torque to 20–30 ft-lbs (27–40.6 N•m).

Crankshaft must be in line with crankshaft at other end of motor.

Torque to 70–80 ft-lbs (95–108 N•m).

Flat side faces up.

132

332637C

Parts

Quantity
Ref

301
302
303
304
305
306★
307
308
309
310
311
312
313
314
315★
316
317
318
320
321
322
325
326▲

Part

24U051
24M008
245795
240724
243951
241278
245971
245972
114699
114672
118444
183169
183210
15C753
114666
106115
246831
246832
193394
193031
15G349
116192
116618
24T878
127301
187437
192840

Description

MOTOR, brushless, double ended, 2 hp
HOUSING, drive, mark vii
HOUSING, bearing
HOUSING, bearing
GEAR, combination, 1595
ROD, connecting
PUMP, displacement, B
PUMP, displacement, A
WASHER, thrust; copper colored
WASHER, thrust; steel colored
SCREW, mach, slot hex wash hd
SPRING, retaining
PIN, str, hdls
SCREW, mach, hex wash hd
SCREW, cap, socket head
WASHER, lock (hi-collar)
PUMP, displacement, A
PUMP, displacement, A
NUT, retaining
NUT, retaining
COVER, drive, plastic, painted
WASHER, thrust
MAGNET
SWITCH, reed, m8 4-pin
SCREW, hxhd, thd cut, 4-40 x .375
LABEL, torque
LABEL, warning

24V152

24V153

2
2

2
2
2
1

1
2
2

1
2
4
12
2
2
10
8
8
1
2
2
2
1
1
2
2
2

1
2

2
4
12
2
2
10
8
8
1
2
2
2
1
1
2
2
2

▲ Replacement Warning labels, signs, tags, and

cards are available at no cost.
★ See Pump Repair manual 309577 for repair
kits.

332637C

133

Parts

Dual Zone 4.0 Kw Fluid Heater
24V145

Torque to 120 ft-lbs (163 N•m).

Torque to 23 ft-lbs (31 N•m).

Apply thermal paste.

Apply pipe sealant and PTFE tape to all non-swiveling threads and threads without o-rings.

5
6

134

Apply lithium grease lubricant to o-rings before assembling in block (1).
Remove tape from probe tip and Orientate sensor as shown. Insert probe until it bottoms on heating element.
Tighten ferrule on sensor probe 3/4 turn past ﬁnger tight or 13 ft-lbs. (17.6 N•m).

332637C

Parts

24V145
Ref

351
352
353
354
355
356
357
358
359
360*
*

Part

15M878
15H302
121319
15H304
15H306
120336
17A092
15B137
15B135
-

Description

BLOCK, horizontal
REDUCER, #14 SAE x
1/2–14 NPT(f)
ADAPTER, 1/2–14 NPT x
#8 JIC
PLUG, 9/16 SAE
ADAPTER, 9/16–18 x
1/8–27 NPT(f)
O-RING, packing
HEATER, immersion,
(2000W, 230V)
SWITCH, over
temperature
MIXER, immersion heater
SENSOR, RTD, 1 kohm,
90°, 4 pin, tip

Qty

1
4
4
2
2
2
1
1
2
2

Ref

Part

Description

361 124131 SCREW, machined, pan
hd, 0.375 in. (9.5 mm),
#6–32
362 15M177 INSULATOR, foam,
heater, horizontal
366 158683 ELBOW, 90°, 1/2–14 NPT
x 1/2–14 NPT
368 124132 O-RING, ﬂuoroelastomer
369 15H305 PLUG, hollow hex 1-3/16
SAE
370* COMPRESSION, 1/8
NPT, SST
371 125644 BRANCH TEE, 1/2 NPT
372 248177 HOUSING, rupture, disc

Qty

2
1
2
4
2
2
2
2

Included in 24L973 Heater RTD Repair Kit.

332637C

135

Parts

Air Control Panel

Apply pipe sealant to all non-swiveling pipe
threads.
Apply anaerobic thread sealant to threads.

Torque to 25 +/- 2 ft-lbs (34 N●m)

Ref

401
402
403
404
136

Part

16H452
277853
117026
113331

Description

BRACKET, air control
BRACKET, mounting,
booth control
SCREW, SHCS, 0.5 in.
(12 mm), M5 x 0.8
VALVE, ball, vented, 1/2 in.

Qty

1
1
2
1

Torque to 10 +/- 2 ft-lbs (14 N●m)

See parts illustration for air ﬂow direction.

Ref

Part

Description

405 190451 UNION, adapter, 1/2 NPT
x 1/2 NPSM
406 158491 NIPPLE, 1/2–14 NPT
407 155470 SWIVEL, union, 90°,
1/2–14 NPSM x 1/2–14
NPT
408 16H482 MANIFOLD, 1/2 NPT x 1/4
NPT

Qty

1
1
1
1

332637C

Parts
Part

Ref

409
410
411
412
413
415
416
417
418
419
▲
★

113796
122161
124287
115841
15T498
116257
116513
116514
104641
156971

Description

Qty

4
7
3
6
3
3
3
3
4
4

SCREW, ﬂanged, hex hd,
0.75 in. (19 mm), 1/4–20
FITTING, air, 1/4 NPT x 3/8
OD
FITTING, adapter, 1/2
npt(m) x #8 JIC(m), ms
FITTING, elbow, 1/4 NPT(f)
x 3/8 OD
FITTING, 90°, swivel, 5/32
OD x 1/8 NPT(f)
GAUGE, pressure, 0–160
psi (0–1 MPa, 0–11 bar)
REGULATOR, air
NUT, regulator, plastic
BULKHEAD, 1 in. (25.4
mm), 3/4–20 x 1/4–18 NPT
NIPPLE, short, 1/4–18 NPT

Ref

420
421
422
423
★
424
★
426
427
428
429
432

Part

125539
114558
16H531

—
—
16K325
16K326
24M665
125625
16K940

Description

UNION, Y, 3/8 OD tubing
COUPLER, line, air, 1/4–18
NPT
FITTING, ﬂow control,
1/4–18 NPT
TUBE, nylon, round, black
HOSE, nylon, 250 psi; see
identiﬁcation table
LABEL, instructions
LABEL, instructions
MODULE, engine controller
TIE, cable, ﬁr tree
LABEL

Qty

1
4
1
1
9
1
1
1
2
1

Replacement Warning labels, signs, tags, and cards are available at no cost.
Included in Tubing Repair Kit 24M650.

424 Identiﬁcation Table
Ref

424–1
424–2
424–3
424–4
424–5
424–6
424–7
424–8
423

Length
in. (mm)

11 (279.4)
13.5 (342.9)
16.5 (419.1)
16 (406.4)
16.5 (419.1)
15 (381)
6.5 (165.1)
5.5 (139.7)
4 (101.6)

332637C

Qty.

1
1
1
1
1
1
1
1
3

137

Parts

Fluid Manifold
24T870

Torque to 355–395 in.-lbs (40–44.6 N●m)

Apply sealant (113500) to threads.

Ref

451
452★
452a★
452b★
453
454
455
456
457
458
461
138

Valve must be closed with handle position as
shown on drawing.
Part

255228
247824
158674
247779
102814
162453
15M669
15J915
15J916
112309
124287

Description

MANIFOLD, ﬂuid
KIT, valve, cartridge, drain
O-RING, BUNA-N
SEAL, seat, valve
GAUGE, press, ﬂuid
FITTING, 1/4 NPSM X 1/4
NPT
SENSOR, pressure, ﬂuid
outlet
HANDLE, red
HANDLE, blue
NUT, hex, jam
FITTING, adapter, 7/8,
1/2–1/4 nptm x #8 JIC

Qty

1
2
1
1
2
2
2
1
1
2

Ref

462
463
464
465
▲
466
▲
★

Apply PTFE tape and thread sealant to gauge
threads.
Apply grease on valve.
Apply PTFE tape or thread sealant to tapered
threads.
Part

121312
100840
111457
189285
150829

Description

ELBOW, male, 3/4 SAE x
1/2 JIC
ELBOW, street, 1/4–18
npt x 1/4–18 npt
O-RING, PTFE
LABEL, hot surface
SPRING, compression

Qty

1
1
2
1
2

Replacement Warning labels, signs, tags,
and cards are available at no cost.
Included in the following complete valve kits:
ISO Valve Kit (left/red) handle 255149.
Resin Valve Kit (right/blue handle) 255150.
Valve Set Kit (both handles and grease gun)
255148.

332637C

Parts

Electrical Enclosure

332637C

139

Parts

Electrical Enclosure
Ref.

501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
✖

140

Part

--24T061
24U855
24U832
24T060
24R757
24R754
123143
122313
117666
121612
121603
126881
126891
120858
120859

Description

ENCLOSURE, electrical,
power
MODULE, BREAKER,
integr reactor
MODULE, TCM
MODULE, MCM
MODULE, disconnect
FAN, COOLING, 80MM,
24VDC
CONNECTOR, power,
male, 2 pin
CONNECTOR, power,
male, 4 pin
BAR, ground, kit
TERMINAL, ground
CONNECTOR, thru, m12,
mxf
GRIP, cord,.51-.71,3/4
BUSHING, strain relief
NUT, bushing
BUSHING, strain relief,
m40 thread
NUT, strain relief, m40
thread

Qty.

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

Ref.

517
518
519
520
521
522
523
524
526
527
528
529
530
531
532

Part

127253
127254
24T174
24R735
121000
125859
194337
16W456
109466
127278
151395
117683
115942
103473
113505

Description

BUSHING, strain relief,
m50 thread
NUT, strain relief, m50
thread
HARNESS, control box
CABLE, CAN power, m12
fem, pigtail
CABLE, CAN, female /
female 0.5m
WIRE, chassis, ground
WIRE, grounding, door
LABEL, identiﬁcation
NUT, lock hex
NUT, keps, hex
WASHER, ﬂat
SCREW, mach, phil pan
hd
NUT, hex, ﬂange head
STRAP, tie, wire
NUT, keps, hex hd

Qty.

1
1
1
1
2
1
1
1
2
4
4
4
8
8
7

See Electrical Schematics, page 154.
Not shown.

332637C

Parts

22kW Diesel Generator

Torque to 26 ft-lbs (35.25 N●m)

Apply sealant (blue) to threads.

Torque to 15 ft-lbs (20 N●m)

Torque to 15–20 in.-lbs (1.7–2 N●m)

Torque to 100 ft-lbs (135.6 N●m)

Torque to 40 ft-lbs (54 N●m)

332637C

Apply lubrication to engine end of hose prior to
assembly.

141

Parts

22kW Diesel Generator
Ref

551
552
556
557
558
559
560
562

563
564
565
568
569
570

Part

—
24R079
16J883
16J884
125532
16H904
16H906
125371
125394
100079
106245
16J799
24L963
113161

Description

ENGINE, diesel, Perkins
ALTERNATOR, 22 kw,
diesel engine
BRACKET, engine mount,
left
BRACKET, engine mount,
right
SCREW, M14 hex head x
30 mm
ENCLOSURE, alternator,
front
ENCLOSURE, alternator,
front
CLAMP, hose, dia.
3/4-1-3/4 in.
ISOLATOR, mount,
radiator, bottom
WASHER, lock, spring
SCREW, cap, sch, 0.625
in. (16 mm) x #8–32
BRACKET, engine relay
KIT, relay, solenoid, 12v,
intermittent
SCREW, ﬂanged, hex hd,
1/2 in. x 1/4–20

Qty.

1
1
1
1
10
1
1
1
2
8
8
1
2
4

Ref

572
572a
572b
572c
575
576
577
579
580
581
582
583
584
585
586
587

Part

Description

24L965 CIRCUIT, breaker, 90A
SCREW
WASHER
NUT
125631 BUSHING, cable, lay-in
strain relief
120858 BUSHING, strain relief,
M40 thread
125625 TIE, cable, ﬁr tree
120859 NUT, strain relief, M40
thread
— See Radiator
120736 SCREW, hex ﬂange hd,
M6 x 1
115942 NUT, hex, ﬂange head
2 in. (50.8
— MUFFLER,
mm) exhaust
125161 MUFFLER, clamp
125685 CAP, exhaust
104572 WASHER, lock spring
105328 SCREW, cap, hex hd, M8
x 1.25

Qty.

1
2
2
2
1
1
4
1
1
2
2
1
1
1
2
2

 Included in Mufﬂer Kit 24L943.
 Included in Complete Coolant Hose Kit 24L939.

See Complete Coolant Hose Kit, page 131.
Replace fuses F6 and F7 located in the junction
box above the 120/240 V alternator. Use Fuse
Replacement Kit 24M723.

142

332637C

Parts

Radiator
See assembly notes on next page.

332637C

143

Parts

Apply pipe sealant to all non-swiveling pipe
threads.

Secure adhesive side of gasket to parts opposing
radiator, not radiator.

Torque to 25 +/- 2 ft-lbs (34 N●m).

See parts list for length.

Torque to 10 +/- 2 ft-lbs (14 N●m).

Torque to 25 in.-lbs (2.8 N●m).

Torque to 40 +/- 2 ft-lbs (54 N●m).

Torque to 15–20 in.-lbs (1.7–2 N●m).

6
7
Ref

Install rubber hose onto bead barb ﬁtting to 0.13
in. (3.3 mm) maximum from hex.
Locate and install edge of hose clamp 0.38 in.
(9.6 mm) maximum from the end of rubber hose.
Part

Description

601 16H872 COVER, radiator mount
602 16H910 GASKET, radiator isolation;
see 602a-602c
602a — GASKET, radiator isolation;
14 in. (355.6 mm), 0.63 in.
dia.
602b — GASKET, radiator isolation;
14 in. (355.6 mm), 2 in. dia.
602c — GASKET, radiator isolation;
3 in. (76.2 mm), 2 in. dia.
603 — RADIATOR
604 16H868 BRACKET, top
605 113161 SCREW, ﬂanged, hex hd;
1/4–20 x 1/2 in. (13 mm)
606 16H870 BRACKET, bottom
607 16H717 FAN, 16 in., 12V
608 16K156 BRACKET, plate
609 125579 ISOLATOR, mount, radiator,
top
610 16H876 BRACKET, support
611 111803 SCREW, cap, hex hd;
3/8–16 x 2 in. (50.8 mm)
612 112958 NUT, hex, ﬂanged
613 16J741 WASHER, nylon, 30% glass
.750 OD
614 — EXCHANGER, heat

144

Qty

1
1
4

1
1
1
1
20
1
1
1
1
1
1
5
4
1

Ref

Apply lubrication to all press-on hoses prior to
assembly.
Loosen all four nuts to approximately 0.18 in.
(4.5 mm) from mounting plate. Place bracket
(638) over nuts and slide down under ﬂange of
nuts until it stops. Re-torque nuts to 25 ft-lbs
(33.8 N●m).
Part

615
616
617
618
619*
620
621
622

623

125356
125139
158383
125171
—
125359
16T800
125371
125370

624
625
626
627
628★
629★

—
125204
16H901
125360
16W156
16W155




Description

FITTING, 1 in. NPT X 1.25
barbed hose
FITTING, barb, beaded
hose
FITTING, union, adapter,
straight
FITTING, modiﬁed, union
FITTING, compression, 1/8
NPT, SST
HOSE, formed, 1 1/4 upper
radiator
HOSE, coolant, 1 in. ID; 6
in. (152.4 mm)
CLAMP, hose, dia. 3/4-1-3/4
in.
CLAMP ,hose, dia.
11/16-1-1/2 in.
TANK, aluminum, coolant
BOTTLE, overﬂow
BRACKET, hose support
HOSE, formed, 1 1/4 lower
radiator
HOSE, coolant, 1 in. ID;
0.271 ft (0.08 m)
HOSE, rubber, 5/16 in. 1.5
ft (0.5 m)

Qty

2
2
3
1
1
1
1
4
2

1
2
1
1
1
1

332637C

Parts

Ref

Part

Description

630 — CAP, radiator; 16 psi (110
kPa, 1.1 bar)
631 24L967 CAP, pressure, coolant,
8-10 psi (55–70 kPa, 0.5–0.7
bar)
632* — SENSOR, RTD 1 K OHM
633 125175 COUPLING, hose, drain
634 125625 TIE, cable, ﬁr tree
635 16N580 HOSE, rubber, 5/16 in., 3.33
ft (1 m)
636 16N581 HOSE, rubber, 5/16 in., 1.25
ft (0.4 m)

Qty

1
1
1
1
2
1
1

Ref

637
638
640
641
642
643★

Part

16M323
16M141
125361
125163
125382
—

Description

GUARD, engine bottom
BRACKET, overﬂow bottle
HOSE, formed, 1–1/4 upper
engine
CLAMP, hose 7/32 in. 5/8in.
HOSE, formed, 1–1/4 lower
engine
HOUSING, ﬁlter

Qty

1
1
1
4

1
1

 included in Heat Exchanger Kit 24L946.

★ Included in Filter Housing Kit 24T027. Order

 Included in Radiator Repair Kit 24L937.

 Included in Coolant Bottle Repair Kit 24L942.
 Included in Radiator Isolator Kit 24L945.

332637C

24T028 for replacement ﬁlter screen (40 mesh).
Included in RTD Sensor Kit 24L974.

 Included in Complete Coolant Hose Kit 24L939.

See Complete Coolant Hose Kit, page 131.

145

Parts

Circuit Breaker Modules
24T061, Din Rail Circuit Breaker Assembly

See Electrical Schematics, page 154.

Torque to 5-8 in.-lbs (0.6-1 N●m)

Torque to 4-5 in.-lbs (0.5-0.6 N●m)

Torque to 23-26 in.-lbs (2.6-3 N●m)

652
653
654
655
656
657
658
659
Ref

146

120838
24R723
24R722
126453
126125
126131
126127
126128
Part

Description

BLOCK, clamp end
BLOCK, terminal, quad M4,
ABB
BLOCK, terminal pe, quad,
ABB
POWER supply, 24V
CIRCUIT, breaker, 2P, 5A,
UL489
CIRCUIT, breaker, 2P, 40A,
UL489
CIRCUIT, breaker, 2P, 15A,
UL489
CIRCUIT, breaker, 2P, 20A,
UL489

Qty

4
2
1
1
1
1
3
2

660
661
662
663
664
665
674

Ref

126130
125668
125669
127302
127303
127304
127308
Part

CIRCUIT, breaker, 2P, 30A,
UL489
BAR, 18 pos, power buss
BAR, bus, connector
BLOCK, terminal, 12.2 mm,
2 wire
BLOCK, terminal, cover
BLOCK, terminal, jumper, 3
position
BLOCK, terminal
Description

Qty

1
1
2
3
1
1
1

332637C

Parts

24T059, Transformer and Fan Circuit Breaker Module

Torque to 5-8 in.-lbs (0.6-1 N●m)

Torque to 23-26 in.-lbs (2.6-3 N●m)

See Electrical Schematics, page 154.
Ref

901
902
903
904
905

Part

--125667
126818
126817
125815

332637C

Description

DIN RAIL
TERMINAL, stop, end
BLOCK, terminal 3-wire
COVER, end
TERMINAL, block, feed
thru

Qty

1
3
2
1
2

Ref

Part

Description

906 24L960 CIRCUIT, breaker, 50
AMP, 2 pole
907 - - - WIRE, cu, electrical, 8
AWG, black
908 - - - FERRULE, wire, 8 AWG

Qty

1
8
4

147

Parts

Fuel Tank
24K390

Ref

751
752
753
754

148

Part

125645
125646
125647

Description

TANK, fuel
GROMMET, tank
GROMMET, tank
FITTING, suction, assy

Qty

1
2
1
1

Ref

Part

Description

755 125648 FITTING, 3/16 barbed
756 125649 VALVE, drain
758 24L955 CAP, fuel

Qty

1
1
1

332637C

Parts

Heat Exchanger Assembly

1
2

Ref
801
802
803
804*
805
*

Ensure ﬂow direction arrows on solenoids
valves (804) are pointing down.
Apply anaerobic pipe sealant to all
non-swiveling ﬁttings before assembling.
Part
16H759
24L917
24L918
24L916
160327

Description
BRACKET, heat
exchanger
EXCHANGER, heat, side
A
EXCHANGER, heat, side
B
VALVE, solenoid, 3/4 NPT,
12 VDC
UNION ADAPTER, 90°

Qty
1
1
1
2
2

Ref
806
807
808
810
811

Part
24J702
24J703
C20487
112958
16J741

Description
KIT, FITTING, outlet, heat
exchanger
KIT, ﬁtting, inlet, heat
exchanger
NIPPLE, hex
NUT, hex, ﬂanged
WASHER, nylon, 30%
glass, 3/4 OD

Qty
1
1
2
8
8

Order 125774 Valve Repair Kit to replace all internal valve parts.
Order 125787 Coil Repair Kit to replace coil.

332637C

149

Parts

Fluid Inlet Kit
24V143

2
Ref

Apply sealant to all tapered pipe threads. Apply
sealant to female threads. Apply to at least the
ﬁrst four threads and approximately 1/4 turn wide.
Apply thermal paste to the stem of dial before
assembling into housing.
Part

Description

851 160327 UNION ADAPTER, 90°
852 15J119 MANIFOLD, strainer,
WYE, inlet
853 102124 THERMOMETER, dial
854 120300 GAUGE, pressure, ﬂuid
855*★ — FILTER, replacement, 20
mesh
856★ C20203 GASKET, Y-strainer,
inlet
857 15H199 PLUG, Y-strainer, , inlet
858 104813 PLUG, pipe
* Optional 80 mesh ﬁlter 255082 (2 pack)

Qty

2
2
2
2
2
2
2
2

Ref

859
862
863
864
865
866
868

Part

15D757
109077
C20487
157785
116504
24U851
16W954

Description

HOUSING, thermometer,
VISCON HP
VALVE, BALL 3/4 NPT
NIPPLE, 1–1/4 in. x 2 in.
3/4 NPT
FITTING, union, swivel
FITTING, tee, run
TRANSDUCER,
pressure, temperature
FITTING, adapter, 3/4
NPT(m) x 3/4 NPT(f)

Qty

2
2
2
4
1
1
1

★ Included in Inlet Filter and Seal Kit 24V020 (20

mesh, 2 pack).

150

332637C

Parts

Switch Box Enclosure

Ref

701
702
703
704
705

Assemble switch blocks as shown.
Part

16W575
121618
121619
120493
120494

332637C

Description

ENCLOSURE, front
SWITCH, start, push
button, green
SWITCH, stop, push
button, red
LATCH, mounting
BLOCK, switch, N.O.

Qty

1
1
1
2
1

Ref

706
707
708
709

Part

120495
260067
117625
16W614

Description

BLOCK, switch, N.C.
FITTING, strain relief, 1/2
npt
NUT, locking
LABEL

Qty

1
1
1
1

151

Parts

Motor Starter

1
2

152

Attach ground connector bar aligned vertically to
electrical box with screw and washer.
Labels from sheet (735).

332637C

Parts

Torque to 38–42 in.-lbs (4.3–4.7 N•m).

Torque to 18–22 in.-lbs (2–2.5 N•m).

Torque to 28–32 in.-lbs (3.1–3.6 N•m).

Ref

721
722
723
724
725
726
727

Part

24U081
24U082
119257
555582
555629
16M826
16X009

Description

STARTER, int. reactor,
3 phase
CONTACT, aux, two no
switches
CONNECTOR, bar,
ground
SCREW, soc hd cap, #10
WASHER, #10, external
tooth lock
CORD, grip, 3/4 in.
CABLE, shunt

Qty

1
1
1
1
1
4
1

Ref

728
729
730
731
732
733
734
735▲

Part

24U080
24U079
16X011
24U078
16X012
24U076
16X010
16X422

Description

CABLE, air compressor
breaker
CABLE, air compressor
CABLE, over
temperature, compressor
CABLE, dryer, breaker
CABLE, power, dryer
CABLE, start-stop
CABLE, pressure vent
LABEL

Qty

1
1
1
1
1
1
1
1

▲ Replacement Warning labels, signs, tags, and

cards are available at no cost.

332637C

153

Electrical Schematics

Electrical Schematics
Harness Identiﬁcation

All wire harnesses are identiﬁed by a letter. The ﬁrst letter on each wire in a wire harness corresponds with the
wire harness. Use the table below to identify the wire harness, system component connections, and wiring
diagram page number(s). The wiring diagram will show every wire included.
Harness
Identiﬁer

C
D
E
F
H
K

M
N
P

Ref

Part

Wiring Diagram

System Components

(90) 24L964 Engine
Center
(280) 16K646 Load
Coolant Valves
(49) 16K301 Engine
Load center
Load Center
(94) 16K297 Engine
Engine Control Module
Load
Center
(53) 16K299 Electrical
Enclosure
Alternator Enclosure
(52) 125753 Electrical Enclosure
MCM
Enclosure
(51) 125752 Alternator
Engine Control Module
Reactor
(54) 125756 Electrical Enclosure
MCM
(519) 24T174 Electrical Enclosure

Engine, page 165
Load Center, page 163
Coolant Valve Wiring Diagram,
page 163
Engine, page 165
Load Center, page 163
Load Center, page 163
Engine, page 165
Engine Control Module, page 164
Load Center, page 163
Electrical Enclosure, page 156
Alternator Enclosure, page 166
Electrical Enclosure, page 156
MCM Wiring Diagram, page 158
Alternator Enclosure, page 166
Engine Control Module, page 164
Reactor, page 162
Electrical Enclosure, page 156
Electrical Enclosure, page 156

Engine Harness Wire Color Code

This table refers to Engine Harness E (49), Engine Control Module Harness F (94), and Disconnect Check
Harness H (53).
Color

Red

Black/White
Orange
White
Gray

154

Purpose

Battery Positive (Lines
Always Energized)
Engine Load Grounds
Starter
Glow Plugs
Fuel Shutoff Solenoid
(FD)

Color

Violet
Black/Yellow
Brown
Dark Blue

Purpose

Radiator Fan
Monitoring Grounds
Oil Pressure Switch
Water Temperature

332637C

Electrical Schematics

Wire Label Identiﬁcation Code

The plastic wire wrap labels applied to many of the cables in the system use a code that indicates both
the near-end and far-end connections made with the labeled wire. The ﬁrst half of the code describes the
module and port that the near-end of the cable connects to. The second half of the code describes where
the far-end of the cable connects. For example, "MCM-2 MOTOR-OT” denotes that the connector nearest
the label connects to the MCM port #2 (“MCM-2” is MCM port #2) and the far-end connects to the motor
overtemperature sensor (“MOTOR-OT” is Motor Overtemperature Sensor). This code is used throughout the
wiring schematics on the following pages.
Circuit Breaker Identiﬁcation
Ref.

Size

CB01

CB02
CB03
CB04
CB05
CB06

15 A
15 A
30 A
20 A
40 A

Component

Power Supply, Fan,
Coolant Circulation Pump
Boost Heat A
Boost Heat B
Hose Heat Primary
Motor Control
Air Compressor
Open

Ref.

CB07
CB08
CB20

Size

20 A
15 A
50 A

Component

Open
Air Dryer
Open
Hose Heat Secondary

Available Circuit Breakers
Part

126123
126124
126125
126126
126127
126128

332637C

Amps

1
3
5
10
15
20

Part

126129
126130
126131
24L960
123668

Amps

25
30
40
50
63

155

30A
20A
40A
20A
15A

K110 RED

H100 ORG
H110 ORG
K100 BLK

24R735

24T174
BREAKER HARNESS

FERRITE
BEAD
16Y509

16
K2
29

FE
B RR
16 EAD ITE
Y5
16

MOTOR 24U049

24T241

15A

DOOR
STUD

CORD GRIP

123652

'CAN-1 ADM'

BULKHEAD
121612

BOX
STUD

CORD GRIP

127253
127254

'TCM-H HT-RTD-H'
H100 ORG
H110 ORG
'24 VDC'

CABLE 16K229
TO LOAD CENTER

CABLE 122837
CABLE 24T241
TO REACTOR BOX

CABLE 24T198
TO CIRC PUMP
TO REACTOR BOX

MOTOR 24U049

15A
N120 BLK
N130 BLK

FERRITE
BEAD
16Y516

BLK

RED

122837

N080 BLK
N060 BLK

CB08
NEUTRAL

CB07

GB02
GROUND BAR
122313

K120 WHT

GB01
GROUND TERMINAL
117666

P080 RED

P070 BLK

K110

K100

P060 RED

P050 BLK

P040 RED

P030 BLK

P020 RED

P010 BLK

N080 BLK

N060 BLK

POWER
SUPPLY

PS1

CB06

P080 RED

P090 GRN / YEL

P070 BLK

CAN 121000

CT01

FERRITE
BEAD
16Y516

CB05

'MCM-CAN-2 CAN-1'

CAN 121000

FERRITE
BEAD
125839

WHT

BLK

CB04

HOSE

N130 BLK

N120 BLK

'TCM H HT-RTD-H'

'TCM-CAN1 PS1'
'TCM-CAN2 MCM'

P060 RED

P050 BLK

P040 RED

P030 BLK

DISCONNECT
24T060

CB03

MCM
24U832

'MCM-CAN-1 TCM'

OVER
TEMP

TCM
24U855

P010 BLK

K120

P020 RED

CB02

FAN 24U848

121603

P100 GRN / YEL

CB01

156
-1

'24 VDC'

BLK

P110

BLU
CIRCUIT BREAKER
DIN RAIL 24T061

BRN
DOOR GROUND WIRE
194337

P110 GRN / YEL

Electrical Schematics

Electrical Enclosure Wiring Diagram
126881
126891

24T241

GRN / YEL
125859

P110 GRN / YEL
P100 GRN / YEL
P090 GRN / YEL

1 BLK
2 BLK
3 BLK
GRN / YEL

ti23006a

332637C

Electrical Schematics

MCM Cable Routing
Item

End 1

End 2

MCMCAN-1 TCM

MCMCAN-1

MCMCAN-2
CAN-1

MCMCAN-2

TCMCAN-2
Electrical
Enclosure
CAN-1
Bulkhead
Motor
Overtemperature
Switch

MCM-2 MOMCM Port 2
TOR-OT
MCM-3
RTDENGINE

MCM Port 3

MCM-4
HX-RTD-A

MCM Port 4

MCM-5
HX-RTD-B

MCM Port 5

MCM-6
PRESSURE-A

332637C

MCM Port 6

Engine RTD
Sensor
Heat
Exchanger
RTD A
Heat
Exchanger
RTD B
Fluid
Manifold
Pressure
Sensor A

Part

Item

121000

MCM-7
PRESSURE-B

MCM Port 7

MCM-8
INLET-A

MCM Port 8

MCM-9
INLET-B

MCM Port 9

121000

End 1

125357

122837

MCM Port
10

125357
125357

127286

MCM-11
LOAD-CTR
MCM-12
CYCLECNT
MCM-14
INSITE

MCM Port
11
MCM Port
12
MCM Port
14

End 2
Fluid
Manifold
Pressure
Sensor B
Temperature and
Pressure Inlet Sensor A
Temperature and
Pressure Inlet Sensor B
Optional
Feed Pump
Shut Off
Solenoids
Load Center
Fluid Motor
Cycle
Counter
InSite
Module

Part
127286

16W131

122030
123656
24T878
24T051

157

158

ti23006a

FERRITE
BEAD
125839

'MCM-12 CYCLE-CNT'
'MCM-6 PRESSURE-A'
'MCM-7 PRESSURE-B'
'MCM-8 INLET-A'
'MCM-9 INLET-B'
122837
125357

127286

24T051

24T878

TO REACTOR BOX
TO REACTOR BOX
122837 'RTD-ENGINE MCM'
125357 'MOTOR-OT MCM'

RTD-ENGINE

125357
125357

16W131

24T051

16W131
TO LOAD CENTER

'PRESSURE-A MCM'

123656

PRESSURE-A

FERRITE
BEAD
119253

127286
127286

127286

16W131
16W131

24T878

CORD GRIP
SENSORS

'PRESSURE-B MCM'

K010 GRN

'INSITE MCM'

PRESSURE-B

MCM
24U832

CORD GRIP
ALTERNATOR

120858
120859

K070 WHT

125753

CABLE 'K' 125753
TO 120/240 VAC
ALTERNATOR

ELECTRICAL ENCLOSURE

GB01
GROUND TERMINAL
117666

DISCONNECT
24T060

INLET
SENSOR A
24U851

PRESSURE
SENSOR A
15M669

MOTOR-OT

MOTOR
24U051

ENGINE
COOLANT
RTD 24L974

INSITE
16X118

'INLET-A MCM'

E-XP2i

INLET
SENSOR B
24U851

PRESSURE
SENSOR B
15M669

FLUID MANIFOLD

'INLET-B MCM'

E-30i

ROTARY SWITCH SETTING

CT01

K050 RED

K030 BLK

MOTOR
CYCLE SWITCH

Electrical Schematics

MCM Wiring Diagram

127253
127254

'MCM-11 LOAD-CTR'

'MCM-14 INSITE'

'MCM-4 HX-RTD-A'

'MCM-5 HX-RTD-B'

'MCM-2 MOTOR-OT'

'MCM-3 RTD-ENGINE'

332637C

332637C
HOSE

TCM
24U855

CAN

126881
126891

WHT
BLK

WHT
BLK
24T242

WHT

125357

BLK

CORD GRIP
SENSORS

261821

24T199

24T242

125357

125358

'HT-A TCM-A'

24T199

HT-RTD-B

'TCM-A HT-A'

BLK

'HT-B TCM-B

16A111

WHT

24T199

HEATER B

RTD A

BLK

24T199

'TCM-B HT-B'

OT SWITCH 15B137

HT-RTD-A

BLK

125358

FERRITE
BEAD
16Y509

CORD GRIP
MOTOR
BOOST HEAT

RTD B

HEATER A

24L973

OVER
TEMP

16A111

24L973

'HT-RTD-A TCM'
ti23006a

BOOST HEATER
24V145

Electrical Schematics

Booster Heater Wiring Diagram
261821

HTR-OT

'HT-RTD-B TCM'

127253
127254

ELECTRICAL ENCLOSURE

'TCM-A HT-RTD-A'
'TCM-B HT-RTD-B'

TCM-OT

159

See Cable Routing Table on page 157.

160

Rotary switch
setting:

E-30i = 0
5

MCM
24U832

'MCM-CAN-2 CAN-1'

121000

122030

'CAN-1 MCM'

SPLITTER
124654

BULKHEAD
121612

CAN 1

123656

123652

'CAN-1 ADM'
BULKHEAD
121612

CAN 2

SOLENOID
16K335

FEED PUMP SHUTOFF

REMOTE DISPLAY
DM 24L952

'ADM-CAN-1 CAN-1'

124003

SPLITTER
125982

123652

ADM 24U854

Electrical Schematics

Optional Remote Display Module and Feed Pump Kit Wiring Diagram

ELECTRICAL ENCLOSURE

ti23006a

E-XP2i = 1

332637C

Electrical Schematics

Optional Customer Auxiliary Power Wiring Diagram
See Circuit Breaker Identiﬁcation, page 155, for circuit breaker identiﬁcation table and other available circuit breakers.
Before making any changes to the standard auxiliary circuit breaker conﬁguration, refer to Circuit Breaker Conﬁguration
Options in the Reactor Operation Manual.

PS1
POWER
SUPPLY

CB04

30A

CB05

20A

120 VAC AUXILIARY LOAD

CIRCUIT BREAKER DIN RAIL 24T061

CB03

15A

240 VAC
AUXILIARY LOAD

CB02

15A

LINE TO LINE WIRING

CB01

240 VAC AUXILIARY LOAD

CB06

40A

LINE TO NEUTRAL WIRING

CB08

120 VAC
AUXILIARY LOAD

15A

L2
120 VAC
AUXILIARY LOAD

CB07

20A

NEUTRAL

ti23006a

332637C

161

162
N120 BLK

BLK
BLK
BLK

RED
RED

BLK
BLK
GRN / YEL
N040

TO HEATED HOSE POWER

TO HEATED HOSE RTD

CABLE 125357
CABLE 24T241
CABLE 122837
HARNESS 24T198
TO POWER DISTRIBUTION BOX

24T198

N080

COOLANT PUMP
24L915

N060

TO POWER
DISTRIBUTION
BOX

HARNESS
24T198

CABLE 24T241
24 VDC

COOLANT PUMP JUNCTION BOX

TO HEATED HOSE POWER

'HT-RTD-H TCM-H'

TRANSFORMER

CORD GRIP
260067

N080- BLK

N060 BLK

N040 GRN / YEL

N130 BLK

N120 BLK

'HT-RTD-H TCM-H'

WHT

BLK

N220 BLK

125357

'HX-RTD-B MCM'

122837

125357

'HX-RTD-A MCM'

N210 BLK

TB24

TB23

SECONDARY

CABINET FAN
24U847

CB20

4
PRIMARY

TB21

N130 BLK

24L972

HX-RTD-B

REACTOR ENCLOSURE

TB22

WHT

HOSE BREAKER
DIN RAIL 24T059

MOTOR FAN
24U847

ti23006a

HEAT EXCHANGER RTD B

HEAT EXCHANGER RTD A

HX-RTD-A

Electrical Schematics

Reactor Cabinet Wiring Diagram

Torque thin terminal block connections to 5–7
in.–lbs (0.5–0.8 N●m).
Torque large terminal block connections to 13–15
in.–lbs (1.4–1.7 N●m).

332637C

Electrical Schematics

Load Center Wiring Diagram
E630 - BLU
E620 - BRN
E611 - BLK
E150 - WHT
E100 - ORG
E200 - GRY
E190 - TAN

FUSE REPAIR KIT
24L959
(contains two replacement fuses)
HAR NESS, 1236 56

E020 - RED
E220 - PUR
E010 - BLK/WHT

RELAY REPAIR KIT
24L958
(contains four replacement relays)

LOAD CENTER REPAIR KIT
24L957

F0 20
F0 10
F0 30
F0 40
F0 70
F0 80
F1 00
F1 10
F1 20

E190
E200
E100
E150
E611
E620
E630

F120 - BLU
F110 - BRN
F100 - BLK/YEL
F080 - PUR
F070 - WHT
F040 - ORG
F030 - GRY
F010 - BLK/YEL
F020 - RED

TO ENGINE
CONTROL
MODULE
HARNESS ‘F’
16K297

‘L O ADC TR -J4 MCM’

TO ENGINE
HARNESS ‘E’
16K301

1
J2

1
J3

CR4

J4
J6 1

LOAD CENTER

D100 - RED
D11 0 - BLK/WH T
D120 - BLU
D130 - BLK/WHT
D140 - GRY
D150 - BLK/WHT

TO COOLANT VALVES (12 VDC)
HARNESS ‘D’
16K646

K1
J5 1

E02 0

E220

H100 - ORG

H110 - ORG

TO ELECTRICAL ENCLOSURE
HARNESS ‘H’
16K299

E010
1

ti23006a

Manual Valve Switch:

o — OFF: Automatic Operation
1 – ON: Manual Operation

Coolant Valve (12 VDC) Wiring Diagram
Load Center

J6–6
J6–5
J6–4
J6–3
J6–2
J6–1

332637C

Harness D (16K646)

D150 — BLK/WHT
D140 — GRY
D130 — BLK/WHT
D120 — BLU
D110 — BLK/WHT
D100 — RED

Connection Description

Bypass valve return
Bypass valve signal
B valve return
B valve signal
A valve return
A valve signal

Coolant Valve Connector

No.

Pin Designations

J18–2
J18–1
J17–2
J17–1
J16–2
J16–1

PIN 2

PIN 1

PIN
UNUSED

163

Electrical Schematics

Engine Control Module Wiring Diagram
TO 120 / 240 VAC
ALTERNATOR
HARNESS 'M', 16Y518

FERRITE
BEAD
125835

RED
BLK
M060

M040

M020

24M665, ENGINE CONTROL MODULE

F120
F110
F100

F080
F070

F040
F030
F020
F010

F010 BLK / YEL

DSE PIN 16

F020 RED
F030 GRY
TO LOAD CENTER
HARNESS 'F', 16K297

F040 GRN
F070 WHT
F080 PUR

ti23006a

F100 BLK / YEL
F110 BRN
F120 BLU

164

332637C

Electrical Schematics

Engine Wiring Diagram
D+

E190 - TAN

E020 - RED

FUSIBLE LINK HARNESS ‘C’, 24L964

B+

12V
CHARGE ALTERNATOR

C020 - RED

C010 - RED

FUSE, 16P405, FUSE HOLDER, 16P406
F9

C030 - RED

C040 - RED
C050 - RED
ENGINE
STARTER
ES

E140 - ORG
E100 - ORG

STARTER
SOLENOID RELAY
CR6
“TOP”

E100 - ORG
E112 - BLK/WHT
C050 - RED

E180 - WHT
E150 - WHT

E150 - WHT

SP4
3

E010 - BLK/WHT

E111 - BLK/WHT
E031

TO LOAD CENTER
HARNESS ‘E’
16K301

E031 - BLK/WHT

GLOW PLUGS

GLOW PLUG
SOLENOID RELAY
CR7
“BOTTOM”

SP2
2

E033 - BLK/WHT

E033

E200 - GRY

FD
FUEL SHUTOFF
SOLENOID

E200 - GRY
E032 - BLK/WHT
J7

SP1
1
E220 - PUR

E220 - PUR
E034 - BLK/WHT

E614

E035

J8
E035 - BLK/WHT
RADIATOR FAN
SINGLE POINT
GROUND
E614 - BLK/YEL
P
E620 - BRN
E611 - BLK/YEL

SP3

E620 - BRN
E612 - BLK/YEL

1
E630 - BLU

OIL PRESSURE SWITCH
J10
T

E630 - BLU
E613 - BLK/YEL
J11

WATER TEMPERATURE
SWITCH

ti23006a

1
2

Splice located inside the 3/4 in. loom above the
starter.
Splice located inside the 3/4 in. loom above
the panel holding CR6 and CR7, near the white
cable tie.
Splice located inside the 3/4 in. loom bottom of
the loop, under CR6 and CR7, approximately 6
in. from the main trunk, Engine Harness (E).
See Repair Fusible Link Harness, page 98, for
fuse or fuse holder repair.

332637C

165

Electrical Schematics

ti23006a

Alternator Enclosure Wiring Diagram
ALTERNATOR ENCLOSURE

K080-WHT
125822

M070-WHT

125631

1
TO ENGINE CONTROL
MODULE

M020-BLK

SP11

BLK

F6, 2 AMP

BLK

1
HARNESS 'M',125752

M040-RED

SP12

F7, 2 AMP

BLK

2
K070-WHT
TO POWER
DISTRIBUTION BOX

K030-BLK

K050 - RED

2
4

1
90 AMP
CB10

K020-BLK
125754
K040-RED
125755

HARNESS 'K',125753
K010 - GRN

120858

120859

F6 and F7 Fuse replacement kit, 24M723.
(contains two fuses)

CB10 circuit breaker replacement kit, 24L965.

166

Two ferrite beads (125835), not shown, are
located on two bundles of wires from the
alternator to the circuit board. These are installed
to eliminate electrical interferences and are
needed to ensure proper operations.
Torque all four wire connections to 40–42 in.-lbs
(4.5–4.7 N●m).

332637C

Electrical Schematics

TI23006a

1
2

ELECTRICAL ENCLOSURE

MOTOR STARTER BOX

START STOP BOX

AIR COMPRESSOR
AND MOTOR ASSEMBLY
16Y567

Air Compressor Wiring Diagram

Tighten all power cable connections to 23–25
in.–lbs (2.6–2.8 N●m).
Torque all air compressor wire connections to
30–32 in.–lbs (3.4–3.6 N●m).

332637C

167

CB04
CB05
CB06
CB07
CB08

15A

30A

20A

40A

20A

15A

GND2
GROUND BAR
122313

PD-GND2

24U080

24U078

ELECTRICAL
ENCLOSURE

CABLE 24U080
TO MOTOR STARTER

CABLE 24U078
TO MOTOR STARTER

WHT
BLK
GRN

CB03

PD-GND2

WHT
BLK
GRN

CB02

NEUTRAL

CB01
CORD GRIP
16M862

CORD GRIP
260067
117625

CORD GRIP
16M862

AC-W1-W5

YEL 4
RED 8
CORD GRIP
260067
117625

24U076

CORD GRIP
260067
117625

16X011

BLK
WHT

AC-OT2

AC-OT1

RED
WHT
BLK

SS-4

STOP
SWITCH

SS-2

SS-3
START
SWITCH

SS-1

OVER
TEMPERATURE
SENSOR

AIR COMPRESSOR OVER TEMPERATURE BOX

AIR COMPRESSOR START STOP BOX

CABLE 16X011
TO MOTOR STARTER

CABLE 24U076
TO MOTOR STARTER

CABLE 24U079
TO MOTOR STARTER

GROUND
STUD

AC-GND

AC-W4-W8

WIRE NUT
#6

MOTOR JUNCTION BOX

WIRE NUT
#6

BLU 1
BLK 5

168
BLK
WHT
GRN

ti23338a
24U079

BREAKER DIN RAIL
24T061

Electrical Schematics

Air Compressor Junction Boxes

PD-N
PD-CB8-4

PD-CB6-2

PD-CB6-4

332637C

Electrical Schematics

Motor Starter
CORD GRIP
16M826

BLK
WHT
MS-QD1

MS-QD1

WHT
24U076

RED
BLK

MS-A2

A2
Motor STARTER
WITH BOX
24U081

CABLE 16X011
TO COMPRESSOR OVER TEMP SENSOR

MS-23

MS-13

16X012

MS-L1
MS-L2
MS-L3

MS-A1
MS-A1

MS-QD2

GRN
BLK
WHT

16X011

CABLE 24U076
TO COMPRESSOR START STOP BOX

AUXILIARY
CONTACTOR
24U082

CABLE 16X012
TO AIR DRYER

16X009 BLK

14
MS-14
MS-24

GROUND BAR
119257

MS-95

95 96

98
MS-GND
MS-GND

MS-QD2

MS-GND

MS-96

CORD GRIP
16M826

GRN
WHT
BLK

MS-T2
MS-T3

MS-98
MS-T1

24U079

CABLE 24U078
TO ELECTRICAL ENCLOSURE
AIR DRYER POWER

CORD GRIP
16M826

WHT
BLK

GRN
CORD GRIP
16M826

24U080

WHT
BLK
16X010

BLK

GRN

24U078

WHT

MS-98

CABLE 24U079
TO AIR COMPRESSOR

CABLE 24U080
TO ELECTRICAL ENCLOSURE
AIR COMPRESSOR POWER

CABLE 16X010
TO AIR EXHAUST VALVE

ti23006a

332637C

169

Repair and Spare Parts Reference

Repair and Spare Parts Reference
Recommended Common Spare Parts
Ref

70
114
115
240
272
273
275
315
452
453
455
569
572
360
370
619
632
643
855
856
-------

170

Part

24K207
16P405
16P406
24L958
24L959
24L972
125774
125787
15C852
15C851
246963
246964
247824
102814
15M669
24L963
24L965
24L973
24L974
24T028
24V020
24M723
24N365
17A101

Description

Hose FTS (Fluid Temperature Sensor)
Fusible Link Fuse (Replacement For
Fusible Link Harness)
Fusible Link Fuse Holder (Replacement
For Fusible Link Harness)
Load Center Relay Repair Kit, for load
center (4 Relays)
Load Center Fuse Repair Kit (2 Fuses)
RTD Repair Kit (A or B Heat Exchangers)
Coolant Valve Repair Kit (includes
diaphragm, seals, and plunger)
Coolant Valve Solenoid Coil Repair Kit
E-30i Pump Repair Kit
E-XP2i Pump Repair Kit
E-XP2i Wet Cup Repair Kit
E-30i Wet Cup Repair Kit
Drain Valve Cartridge
Fluid Pressure Gauge
Pressure Sensor
Engine Solenoid Relay Kit
90 A Circuit Breaker Kit (For Generator
Junction Box)
RTD Repair Kit (Booster Heater)
RTD Repair Kit (Engine Heat Exchanger)
Coolant Filter Kit (one 40 mesh screen)
Y-Strainer Filter and Gasket Kit, 20 mesh
(2 pack)
Fuse Replacement Kit (For Generator
Junction Box)
RTD Cable Test Kit (To assist measuring
RTDs and RTD cable resistances)
Compressor Oil (1 gallon)

Part of Assembly

Systems
Systems
Systems
Proportioner
Proportioner
Proportioner
Proportioner
Heat Exchanger Assembly
Proportioner
Heat Exchanger Assembly
Proportioner Module
Proportioner Module
Proportioner Module
Proportioner Module
Fluid Manifold
Fluid Manifold
Fluid Manifold
Diesel Generator
Diesel Generator
Heater
Radiator
Radiator
Fluid Inlet Kit
Diesel Generator
Heated Hose and FTS
Air Compressor Systems

332637C

Recommended Rebuild Spare Parts

Recommended Rebuild
Spare Parts
Ref.

27
504
212
231
240
275
804
416
423
424
503
506
656
657
658
659
660
906
---

332637C

Part

24U854
24U832
24R756
24L915
24L957
24L916
116513
24M650
24U855
24R757
126125
126131
126127
126128
126130
24L960
24L939

Description

Advanced Display Module (ADM)
Motor Control Module (MCM)
Cooling Fan, Motor and Lower Cabinet
Coolant Circulation Pump
Load Center Repair Kit
Coolant Valve (complete)
Air Regulator
Air Control Tubing Repair Kit (includes full
length of air control tubing)
Temperature Control Module (TCM)
Cooling Fan, Electrical Enclosure
5A Circuit Breaker
40A Circuit Breaker
15A Circuit Breaker
20A Circuit Breaker
30A Circuit Breaker
50A Circuit Breaker
Complete Coolant Hose Kit (includes all
coolant hoses)

Part of Assembly

System
Proportioner
Proportioner
Proportioner
Proportioner
Proportioner
Heat Exchanger Assembly
Air Control Panel
Air Control Panel
Electrical Enclosure
Electrical Enclosure
Electrical Enclosure
Electrical Enclosure
Electrical Enclosure
Electrical Enclosure
Electrical Enclosure
Transformer and Fan Circuit Breaker
Module
See Complete Coolant Hose Kit in manual

171

Dimensions

Figure 47

172

332637C

Dimensions

Figure 48

Figure 49

332637C

173

Dimensions

Figure 50 Floor Mount Hole Pattern

174

332637C

Technical Specifications

Technical Speciﬁcations
Reactor 2 Elite Integrated Proportioning Systems

Maximum Fluid Working Pressure

E-30i
E-XP2i

Maximum Fluid Temperature

E-30i
E-30i with booster heater
E-XP2i
Maximum Output

E-30i
E-XP2i

Maximum Heated Hose Length

Length

U.S.

Metric

2000 psi
3500 psi

14 MPa, 140 bar
24.1 MPa, 241 bar

150°F
180°F
180°F

65°C
82°C
82°C

30 lb/min
2 gpm

13.5 kg/min
7.6 lpm

310 ft

94 m

0.0272 gal.
0.0203 gal.

0.1034 liter
0.0771 liter

20° to 120°F

-7° to 49°C

Output per Cycle

A and B

E-30i
E-XP2i

Operating Ambient Temperature Range

Temperature

Auxiliary Power Available

Voltage
Engine

Model

Alternator

Model

Battery Requirements

120 Vac or 240 Vac, 60 Hz
Perkins 404–22G, 2.2 L, 29 HP
Mecc Alte 22 kW, 240 V, 1 PH, 60 Hz, pancake style

Voltage
Minimum Cold Cranking Amps

12 Vdc
800 CCA

Connection Type

Post Style

332637C

175

Technical Specifications

Reactor 2 Elite Integrated Proportioning Systems
Metric

U.S.
Recommended Battery Size

BC Group Number
Length
Width
Height

10.25 in.
6.81 in.
7.88 in.

Booster Heater Power

E-30i
E-30i with booster heat
E-XP2i

260 mm
173 mm
200 mm
None
4000 Watts
4000 Watts

Rotary Vane Air Compressor
Hydrovane Model V04 (PURS type), continuous run

Part No.

025CK10

Pressure

140 psi

Speciﬁcations
Required Features

0.9 MPa, 9.6 bar)
16 cfm
Thermal overload switch
Safety Relief Valve

Motor: Baldor

Part No.
Speciﬁcations
Required Features

EL1410–CUS
5 HP, 1735 RPM, 240 V, 1 Phase, OPSB
C face, lift rings,

Refrigerated Air Dryer

Hankison Model H1T20
Speciﬁcations
Required Features

115VAC, 1 Phase, 60 Hz, 22 scfm at 150 psi (1 MPa, 10.3 bar)
Pilot valve unloader

Noise

Sound Pressure measured per ISO-9614–2.

Sound Pressure measured from
3.1 ft (1 m), at 1500 psi (10 MPa,
103 bar), 2 gpm (7.6 lpm)
Fluid Inlets

Component A (ISO) and
Component B (RES)
Fluid Outlets

Component A (ISO)
176

91.0 dBA
3/4 NPT(f) with 3/4 NPSM(f) union
#8 (1/2 in.) JIC, with #5 (5/16 in.) JIC adapter
332637C

Technical Specifications

Reactor 2 Elite Integrated Proportioning Systems

Component B (RES)
Fluid Circulation Ports

Size
Maximum Pressure
Weight

E-30i
E–30i with compressor and dryer
E-30i with booster heat
E–30i with booster heat,
compressor, and dryer
E-XP2i
E–XP2i with compressor and dryer
Wetted Parts

Material

332637C

U.S.

Metric

#10 (5/8 in.) JIC, with #6 (3/8 in.) JIC adapter
1/4 NPSM(m), with sst braided tubing
250 psi
1.75 MPa, 17.5 bar
1750 lb
2200 lb
1800 lb
2250 lb

794 kg
998 kg
816 kg
1021 kg

1800 lb
2200 lb

816 kg
998 kg

Aluminum, stainless steel, zinc plated carbon steel, brass,
carbide, chrome, chemically resistant o-rings, PTFE, ultra-high
molecular weight polyethylene

177

Notes

178

332637C

Graco Extended Warranty for Integrated Reactor®
2 Components
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its
name to be free from defects in material and workmanship on the date of sale to the original purchaser for use.
With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of
twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be
defective. This warranty applies only when the equipment is installed, operated and maintained in accordance
with Graco’s written recommendations.
Description
Warranty Period
Graco Part Number
24U050
Electric Motor
36 Months or 3 Million Cycles
24U051
Electric Motor
36 Months or 3 Million Cycles
24U831
Motor Control Module
36 Months or 3 Million Cycles
24U832
Motor Control Module
36 Months or 3 Million Cycles
24U855
Heater Control Module
36 Months or 3 Million Cycles
24U854
Advanced Display Module
36 Months or 3 Million Cycles
All other Reactor 2 parts
12 Months
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction,
damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper
maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco
be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures,
accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation,
operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized
Graco distributor for veriﬁcation of the claimed defect. If the claimed defect is veriﬁed, Graco will repair or replace
free of charge any defective parts. The equipment will be returned to the original purchaser transportation
prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be
made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS
FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The
buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost
proﬁts, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available.
Any action for breach of warranty hereunder must be brought within the latter of two (2) years of the date of
sale, or one (1) year the warranty period expires.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT,
MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not
manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of
their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of
these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco
supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold
hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices
and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be
drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en
Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou
en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com.
To place an order, contact your Graco Distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reﬂects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
For patent information, see www.graco.com/patents.
Original Instructions. This manual contains English. MM 332637
Graco Headquarters: Minneapolis
International Ofﬁces: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision C, April 2014

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Keywords                        : 332637,  Reactor 2 Elite Integrated Proportioning System, Repair-Parts, Reactor 2 E-30i, Reactor 2 E-, 332637C, 332637EN, 332637EN-C
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Creator                         : Emil Meindl
Title                           : 332637C - Reactor 2 Elite Integrated Proportioning System, Repair-Parts, English
Description                     : 332637C - Reactor 2 Elite Integrated Proportioning System, Repair-Parts, English
Subject                         : 332637, Reactor 2 Elite Integrated Proportioning System, Repair-Parts, Reactor 2 E-30i, Reactor 2 E-, 332637C, 332637EN, 332637EN-C
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Author                          : Emil Meindl

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Graco 332637C Reactor 2 Elite Integrated Proportioning System Users Manual System, Repair Parts, English

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